Fiber optic connector, fiber optic connector and cable assembly, and methods for manufacturing

ABSTRACT

A fiber optic cable and connector assembly including a fiber optic connector mounted at the end of a fiber optic cable. The fiber optic connector includes a ferrule assembly including a stub fiber supported within a ferrule. The stub fiber is fusion spliced to an optical fiber of the fiber optic cable at a location within the fiber optic connector.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 13/772,059,filed Feb. 20, 2013, which application claims the benefit of U.S.Provisional Patent Application Ser. No. 61/691,621, filed Aug. 21, 2012,U.S. Provisional Patent Application Ser. No. 61/666,683, filed Jun. 29,2012, U.S. Provisional Patent Application Ser. No. 61/661,667, filedJun. 19, 2012 and U.S. Provisional Patent Application Ser. No.61/600,915, filed Feb. 20, 2012, which applications are herebyincorporated herein by reference in their entireties.

TECHNICAL FIELD

The present disclosure relates generally to optical fiber communicationsystems. More particularly, the present disclosure relates to fiberoptic connectors, fiber optic connector and cable assemblies and methodsfor manufacturing.

BACKGROUND

Fiber optic communication systems are becoming prevalent in part becauseservice providers want to deliver high bandwidth communicationcapabilities (e.g., data and voice) to customers. Fiber opticcommunication systems employ a network of fiber optic cables to transmitlarge volumes of data and voice signals over relatively long distances.Optical fiber connectors are an important part of most fiber opticcommunication systems. Fiber optic connectors allow two optical fibersto be quickly optically connected and disconnected.

A typical fiber optic connector includes a ferrule assembly supported ata front end of a connector housing. The ferrule assembly includes aferrule and a hub mounted to a rear end of the ferrule. A spring is usedto bias the ferrule assembly in a forward direction relative to theconnector housing. The ferrule functions to support an end portion of atleast one optical fiber (in the case of a multi-fiber ferrule, the endsof multiple fibers are supported). The ferrule has a front end face atwhich a polished end of the optical fiber is located. When two fiberoptic connectors are interconnected, the front end faces of theirrespective ferrules abut one another and the ferrules are forcedtogether by the spring loads of their respective springs. With the fiberoptic connectors connected, their respective optical fibers arecoaxially aligned such that the end faces of the optical fibers directlyoppose one another. In this way, an optical signal can be transmittedfrom optical fiber to optical fiber through the aligned end faces of theoptical fibers. For many fiber optic connector styles, alignment betweentwo fiber optic connectors is provided through the use of a fiber opticadapter that receives the connectors, aligns the ferrules andmechanically holds the connectors in a connected orientation relative toone another.

A fiber optic connector is often secured to the end of a correspondingfiber optic cable by anchoring a tensile strength structure (e.g.,strength members such as aramid yarns, fiberglass reinforced rods, etc.)of the cable to the connector housing of the connector. Anchoring istypically accomplished through the use of conventional techniques suchas crimps or adhesive. Anchoring the tensile strength structure of thecable to the connector housing is advantageous because it allows tensileload applied to the cable to be transferred from the strength members ofthe cable directly to the connector housing. In this way, the tensileload is not transferred to the ferrule assembly of the fiber opticconnector. If the tensile load were to be applied to the ferruleassembly, such tensile load could cause the ferrule assembly to bepulled in a proximal direction against the bias of the connector springthereby possibly causing an optical disconnection between the connectorand its corresponding mated connector. Fiber optic connectors of thetype described above can be referred to as pull-proof connectors. Inother connector styles, the tensile strength layer of the fiber opticcable can be anchored to the hub of the ferrule assembly.

Connectors are typically installed on fiber optic cables in the factorythrough a direct termination process. In a direct termination process,the connector is installed on the fiber optic cable by securing an endportion of an optical fiber of the fiber optic cable within a ferrule ofthe connector. After the end portion of the optical fiber has beensecured within the ferrule, the end face of the ferrule and the end faceof the optical fiber are polished and otherwise processed to provide anacceptable optical interface at the end of the optical fiber. A directtermination is preferred because it is fairly simple and does not havelosses of the type associated with a spliced connection.

A number of factors are important with respect to the design of a fiberoptic connector. One aspect relates to ease of manufacturing andassembly. Another aspect relates to connector size and compatibilitywith legacy equipment. Still another aspect relates to the ability toprovide high signal quality connections with minimal signal degradation.

SUMMARY

The present disclosure relates to fiber optic connectors having in-bodyfusion splices. In certain embodiments, the connectors are configured tobe fully compatible with legacy equipment such as standard patch panelsand standard fiber optic adapters. In other embodiments, such connectorscan include factory fusion splices. In certain embodiments, theconnectors are in full compliance with Telcordia GR-326 or similarstringent industry or customer specifications (e.g., TIA-EIA 568-C.3;IEC 61753-X; and IEC 61755-X). In certain embodiments, the connectorsare in compliance with Telcordia GR-326 or similar stringent industry orcustomer specifications with respect to length and side load testing. Incertain embodiments, such connectors are less than or equal to theGR-326 requirement of 57 millimeters in length.

Various methods of manufacture are disclosed for making the disclosedconnectors and other components. In one method, an injection moldingprocess is used in which ultraviolet (UV) light curable material isintroduced into a mold cavity formed by a pair of molding blocks whereinthe material is cured by a UV light while still within the mold cavity.In one embodiment, the process is used to form an overmolded part onto acomponent. In one embodiment, the component is a ferrule in a fiberoptic connector.

A variety of additional aspects will be set forth in the descriptionthat follows. The aspects relate to individual features and tocombinations of features. It is to be understood that both the foregoinggeneral description and the following detailed description are exemplaryand explanatory only and are not restrictive of the broad inventiveconcepts upon which the embodiments disclosed herein are based.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front, perspective, cross-sectional view of a ferruleassembly in accordance with the principles of the present disclosure;

FIG. 2 is a rear, perspective view of the ferrule assembly of FIG. 1;

FIG. 3 is a longitudinal cross-sectional view of the ferrule assembly ofFIG. 1 with a dust cap installed on the ferrule;

FIG. 4 is a cross-sectional view taken along section line 4-4 of FIG. 3,the cross-sectional view shows a bare fiber portion of an optical fiberof the ferrule assembly;

FIG. 5 is a cross-sectional view taken along section line 5-5 of FIG. 3,the cross-section shows a coated fiber portion of the ferrule assembly;

FIG. 6 is a cross-sectional view showing an alternative configurationfor the coated fiber portion of FIG. 5;

FIG. 7 is a flow chart illustrating a process sequence for manufacturingthe ferrule assembly of FIG. 1;

FIG. 8 is a side view showing the ferrule assembly of FIG. 1 in theprocess of being polished at a polishing table;

FIG. 9 is a top view of the ferrule assembly and polishing table of FIG.8;

FIG. 10 shows the ferrule assembly of FIG. 1 in the process of beingtuned with respect to core concentricity;

FIG. 11 is an end view of the ferrule assembly of FIG. 1 with theferrule marked for the purpose of core concentricity tuning;

FIG. 12 is a graph used as a tool for determining the direction of coreoffset established during core concentricity tuning;

FIG. 13 is a front, perspective, cross-sectional view of a fiber opticconnector and cable assembly in accordance with the principles of thepresent disclosure;

FIG. 14 is another cross-sectional view of the fiber optic connector andcable assembly of FIG. 13, the connector is shown without a dust cap;

FIG. 15 is a longitudinal, cross-sectional view of the fiber opticconnector and cable assembly of FIG. 13;

FIG. 16 is a flow chart illustrating a sequence of steps for factorymanufacturing the fiber optic connector and cable assembly of FIG. 13;

FIG. 17 shows the ferrule assembly of FIG. 1 being held for stripping,cleaning and laser cleaving;

FIG. 18 shows the fiber optic cable of the fiber optic connector andcable assembly of FIG. 13 with its optical fiber being held forstripping, cleaning and laser cleaving;

FIG. 19 shows the optical fiber of the ferrule assembly of FIG. 1 incoarse alignment of the optical fiber of the fiber optic cable;

FIG. 20 shows the ferrule fiber precisely aligned with the fiber opticcable fiber, the aligned fibers are shown at an arc treatment station,arc shielding is also shown;

FIG. 21 shows the arrangement of FIG. 20 with the shielding lowered toprotect the ferrule and coated portions of the fibers when the arctreatment device is activated to form a fusion splice between thealigned optical fibers;

FIG. 22 shows the arrangement of FIG. 21 after an initial protectiveovercoat or over mold layer has been formed over the fusion splice;

FIG. 23 shows the arrangement of FIG. 22 after a hub has been overmolded over the rear portion of the ferrule of the ferrule assembly andalso over the splice between the aligned fibers;

FIG. 24 is a cross-sectional view illustrating a mold for forming theover molded hub of FIG. 23;

FIG. 25 is a perspective view of the ferrule assembly of FIG. 1 splicedto the fiber optic cable and over molded with the hub;

FIG. 26 is a front end view of another fiber optic connector inaccordance with the principles of the present disclosure;

FIG. 27 is a cross-sectional view taken along section line 27-27 of FIG.26;

FIG. 27A is an enlarged view of a portion of FIG. 27;

FIG. 28 is a front end view of a further fiber optic connector inaccordance with the principles of the present disclosure;

FIG. 29 is a cross-sectional view taken along section line 29-29 of FIG.28;

FIG. 29A is an enlarged view of a portion of FIG. 29;

FIG. 30 is a front end view of another fiber optic connector inaccordance with the principles of the present disclosure;

FIG. 31 is a cross-sectional view taken along section line 31-31 of FIG.30;

FIG. 31A is an enlarged view of a portion of FIG. 31;

FIG. 32 is a front end view of a further fiber optic connector inaccordance with the principles of the present disclosure;

FIG. 33 is a cross-sectional view taken along section line 33-33 of FIG.32;

FIG. 33A is an enlarged view of a portion of FIG. 33;

FIG. 34 is a front end view of another fiber optic connector inaccordance with the principles of the present disclosure;

FIG. 35 is a cross-sectional view taken along section line 35-35 of FIG.34;

FIG. 35A is an enlarged view of a portion of FIG. 35;

FIGS. 36-40 show an example manufacturing sequence for splicing a fiberstub of a ferrule to a fiber of a cable and for enclosing the splice anda portion of the ferrule within a composite hub suitable for use in anyof the fiber optic connectors disclosed herein;

FIG. 41 illustrates a multi-fiber ferrule suitable for use withmulti-fiber connectors in accordance with the principles of the presentdisclosure, the multi-fiber ferrule is shown supporting an optical fiberstub having a plurality of optical fibers;

FIG. 42 illustrates a multi-fiber optical connector incorporating themulti-fiber ferrule of FIG. 41;

FIGS. 43-48 illustrate a sequence of steps for preparing a multi-fiberoptical cable for splicing to the optical fiber stub of the multi-fiberferrule of FIG. 41;

FIGS. 49-51 show a sequence of process steps for preparing the opticalfiber stub of the multi-fiber ferrule of FIG. 41 for splicing to themulti-fiber cable of FIGS. 43-48;

FIG. 52 is a perspective view of a fusion splicing tray in accordancewith the principles of the present disclosure for use in fusion splicingthe multi-fiber cable of FIGS. 43-48 to the fiber stub of the ferrule ofFIG. 41;

FIG. 53 is a top view of the fusion splicing tray of FIG. 52;

FIG. 53A is an enlarged view of a portion of FIG. 53;

FIG. 54 is a cross-sectional view taken along section line 54-54 of FIG.53;

FIG. 54A is an enlarged view of a portion of FIG. 54; and

FIGS. 55-62 show a sequence of steps for assembling the multi-fiberconnector of FIG. 42 after the fiber stub of the multi-fiber ferrule ofFIG. 41 has been spliced to the multi-fiber cable of FIGS. 43-48;

FIGS. 63-67 show an alternative embodiment showing a manufacturingsequence for splicing a fiber stub of a ferrule to a fiber of a cableand for enclosing the splice and a portion of the ferrule within acomposite hub suitable for use in any of the fiber optic connectorsdisclosed herein according to the principles of the present invention;

FIG. 68 is a pre-assembled depiction of a ferrule and flange accordingto the principles of the present invention;

FIG. 69 is a side view of FIG. 68;

FIG. 70 is a cross-sectional view taken along section line 70-70 of FIG.69;

FIG. 71 is a top view of FIG. 68;

FIG. 72 is a perspective view of the ferrule assembly of FIGS. 63-65spliced to the fiber optic cable and over molded with the hub;

FIG. 73 is a side view of FIG. 72; and

FIG. 74 is a cross-sectional view taken along section line 74-74 of FIG.73;

FIG. 75 is a front perspective view of an embodiment of a mold assemblyaccording to the principles of the present disclosure;

FIG. 76 is a side view of the mold assembly shown in FIG. 75

FIG. 77 is a bottom perspective view of the mold assembly shown in FIG.75;

FIG. 78 is a cross-sectional view of the mold assembly shown in FIG. 75;

FIG. 79 is an enlarged cross-sectional view from a portion of the moldassembly view depicted in FIG. 78;

FIG. 80 is a top view of a cavity portion of an upper part of the moldassembly shown in FIG. 75;

FIG. 81 is a top view of a cavity portion of a lower part of the moldassembly shown in FIG. 75;

FIG. 82 is a flow chart of an injection molding process usable with themold assembly shown in FIG. 75;

FIG. 83 is an exploded view of another ferrule and hub assembly inaccordance with the principles of the present disclosure;

FIG. 84 is a partially assembled view of the ferrule and hub assembly ofFIG. 83;

FIG. 85 is a side view of the ferrule assembly of FIG. 83 with a fronthub portion over molded over the ferrule;

FIG. 86 is a rear, perspective view of the ferrule assembly and fronthub portion of FIG. 85;

FIG. 87 is an exploded view of a further ferrule and hub assembly inaccordance with the principles of the present disclosure;

FIG. 88 shows the ferrule and hub assembly of FIG. 87 in a partiallyassembled configuration;

FIG. 89 is a perspective view of a shell of the ferrule and hub assemblyof FIGS. 87 and 88;

FIG. 90 is an exploded view of still another ferrule and hub assembly inaccordance with the principles of the present disclosure;

FIG. 91 shows an alternative hub shell that can be used with the ferruleand front hub portion of the embodiment of FIGS. 87 and 88;

FIG. 92 is an exploded view illustrating an LC-style connectorincorporating the ferrule and hub assembly of FIGS. 83 and 84; and

FIG. 93 is a cross-sectional view of the connector of FIG. 92.

DETAILED DESCRIPTION

FIGS. 1 and 2 illustrate a ferrule assembly 20 in accordance with theprinciples of the present disclosure. The ferrule assembly 20 includes aferrule 22 and an optical fiber stub 24 secured to the ferrule 22. Theoptical fiber stub 24 can be referred to as a “first optical fiber.” Theferrule 22 includes a front end 26 positioned opposite from a rear end28. The front end 26 preferably includes an end face 30 at which aninterface end 32 of the optical fiber stub 24 is located. The ferrule 22defines a ferrule bore 34 that extends through the ferrule 22 from thefront end 26 to the rear end 28. The optical fiber stub 24 includes afirst portion 36 secured within the ferrule bore 34 and a second portion38 that extends rearwardly from the rear end 28 of the ferrule 22. Thesecond portion 38 can be referred to as a “pigtail” or as a “free endportion.”

The ferrule 22 is preferably constructed of a relatively hard materialcapable of protecting and supporting the first portion 36 of the opticalfiber stub 24. In one embodiment, the ferrule 22 has a ceramicconstruction. In other embodiments, the ferrule 22 can be made ofalternative materials such as Ultem, thermoplastic materials such asPolyphenylene sulfide (PPS), other engineering plastics or variousmetals. In example embodiments, the ferrule 22 has a length L1 in therange of 5-15 millimeters (mm), or in the range of 8-12 mm.

The first portion 36 of the optical fiber stub 24 is preferably securedby an adhesive (e.g., epoxy) within the ferrule bore 34 of the ferrule22. The interface end 32 preferably includes a polished end faceaccessible at the front end 32 of the ferrule 22.

Referring to FIG. 3, the ferrule bore 34 has a stepped-configurationwith a first bore segment 40 having a first diameter d1 and a secondbore segment 42 having a second diameter d2. The second diameter d2 islarger than the first diameter d1. A diameter step 44 provides atransition from the first diameter d1 to the second diameter d2. Thefirst bore segment 40 extends from the front end 26 of the ferrule 22 tothe diameter step 44. The second bore segment 42 extends from thediameter step 44 toward the rear end 28 of the ferrule 22. The ferrulebore 34 also includes a conical transition 39 that extends from thesecond bore segment 42 to the rear end 28 of the ferrule 22. In certainembodiments, the first diameter d1 is about 125.5 microns with atolerance of +1 micron. In certain embodiments, the second diameter d2can be about 250 microns so as to accommodate a coated optical fiber, orabout 900 microns so as to accommodate a coated and buffered opticalfiber. In one example, d1 is in the range of 230-260 microns and d2 isin the range of 500-1100 microns.

The first portion 36 of the optical fiber stub 24 includes a bare fibersegment 46 that fits within the first bore segment 40 of the ferrule 22and a coated fiber segment 48 that fits within the second bore segment42 of the ferrule 22. The bare fiber segment 46 is preferably bare glassand, as shown at FIG. 4, includes a core 47 surrounded by a claddinglayer 49. In a preferred embodiment, the bare fiber segment 46 has anouter diameter that is no more than 0.4 microns smaller than the firstdiameter d1. In certain embodiments, the coated fiber segment 48includes one or more coating layers 51 surrounding the cladding layer 49(see FIG. 5). In certain embodiments, the coating layer or layers 51 caninclude a polymeric material such as acrylate having an outer diameterin the range of about 230-260 microns. In still other embodiments, thecoating layer/layers 51 can be surrounded by a buffer layer 53 (e.g., atight or loose buffer layer) (see FIG. 6) having an outer diameter inthe range of about 500-1100 microns.

The second portion 38 of the optical fiber stub 24 preferably has alength L2 that is relatively short. For example, in one embodiment, thelength L2 of the second portion 38 is less than the length L1 of theferrule 22. In still other embodiments, the length L2 is no more than 20mm, or is no more than 15 mm, or is no more than 10 mm. In still otherembodiments, the length L2 of the second portion 38 is in the range of1-20 mm, or in the range of 1-15 mm, or in the range of 1-10 mm, or inthe range of 2-10 mm, or in the range of 1-5 mm, or in the range of 2-5mm, or less than 5 mm, or less than 3 mm, or in the range of 1-3 mm.

FIG. 7 outlines a process for manufacturing the ferrule assembly 20 ofFIGS. 1-3. The manufacturing process begins at step 100 where theferrule 22 is fed to a processing station or location. It will beappreciated that the ferrule 22 can be fed by an automated feedmechanism such as a bowl feed mechanism.

Once the ferrule 22 has been selected and fed or otherwise moved to theprocessing station, the inner diameter of the ferrule 22 is preferablymeasured (see step 102). For example, the first diameter d1 defined bythe first bore segment 40 of the ferrule bore 34 is preferably measured.An automated ferrule handler (e.g., a gripper/holder 37 as shownschematically at FIG. 8) can receive the ferrule 22 from the automatedfeed mechanism and can hold and/or manipulate the ferrule 22 duringmeasurement.

Once the first diameter d1 of the ferrule bore 34 has been determined,an optical fiber suitable for insertion within the ferrule is selected(see step 104). Preferably, a plurality of fiber spools 60 a-60 d isprovided at the processing station. Each of the fiber spools 60 a-60 dincludes a separate optical fiber 62 a-62 d. Each of the optical fibers62 a-62 d preferably has a different cladding outer diameter. It isdesirable to select the optical fiber 62 a-62 d having a cladding outerdiameter that is closest to the measured diameter d1 of the ferrule 22.In certain embodiments, the measured first diameter d1 is no more than0.4 microns larger than the cladding outer diameter of the selectedoptical fiber 62 a-62 d.

To enhance core concentricity with respect to the outer diameter of theferrule 22, it is desirable for the optical fibers 62 a-62 d to be highprecision optical fibers in which parameters such as cladding outerdiameter and core-to-cladding concentricity are manufactured torelatively tightly tolerance. In certain embodiments, each of theoptical fibers 62 a-62 d has an outer cladding diameter manufacturedwithin a tolerance of +/−0.7 microns and also has a core-to-claddingconcentricity offset less than or equal to 0.5 microns (i.e., the centerof the core is offset from the center of the cladding diameter by nomore than 0.5 microns). The ferrule 22 is also preferably manufacturedto relatively precise tolerance specifications. For example, in oneembodiment, the diameter d1 of the ferrule has a dimension of 125.5microns plus 1.0 micron, minus 0.0 microns. Additionally, the ferrule 22can have a fiber bore to outer diameter concentricity offset less thanor equal to 1 micron (i.e., the center of the ferrule bore is offsetfrom the center of the outer diameter of the ferrule by no more than 1micron). By using a precision ferrule in combination with a precisionoptical fiber, and by having several different sized precision opticalfibers from which to select the optical fiber to be inserted in theferrule, it is possible to optimize concentricity of the optical fiberwithin the ferrule 22 without rotational tuning and even more so withrotational tuning. In one economically reasonable embodiment, fourfibers of known diameters of 125.3 microns, 125.6 microns, 125.9microns, and 126.2 microns could be employed to match the ferrule innerdiameter to within 0.2 to 0.3 microns. By using this fiber selectionprocess as part of the manufacturing process, it is possible for all ofthe ferrule assemblies 20 output from the manufacturing process to havea measured first diameter d1 that is no more than 0.4 microns largerthan the cladding outer diameter of the selected optical fiber 62 a-62d. Those that fall outside of the tolerance can be rejected, but becauseof the process only a relatively small number may fall outside of thetolerance thereby enhancing the cost effectiveness of the process. Inother embodiments, the ferrule assemblies 20 manufactured and outputaccording to the process can have measured first diameters d1 that onaverage are no more than 0.4 microns larger than the cladding outerdiameters of the selected optical fiber 62 a-62 d.

Once the optical fiber 62 a-62 d of the appropriate diameter has beenselected, the optical fiber is cut to length to form the stub opticalfiber 24 (see step 106). In certain embodiments, the cut optical fiber24 has a length less than 40 microns. In other embodiments, the opticalfiber 24 has a length less than 30 microns, or less than 25 microns, orless than 20 microns, or less than 15 microns. In still otherembodiments, the cut optical fiber has a length in the range of 12-25microns.

At step 108, the optical fiber 24 is stripped. By stripping the opticalfiber 24, the bare fiber segment 46 is exposed. The bare fiber segment46 preferably includes a glass core 47 and cladding 49 as shown at FIG.4. The cutting and stripping steps can be automated.

After stripping of the optical fiber 24, epoxy is dispensed into theferrule bore 34 of the ferrule 22 (see step 110), and the optical fiber24 is inserted into the ferrule bore 34. Because of the relatively tighttolerance between the first diameter d1 of the bare fiber segment 46 ofthe optical fiber stub 24 and the first portion 36 of the fiber bore 34,surface tension between the epoxy within the ferrule bore 34 and theoptical fiber stub 24 provides a self-centering function that assists incentering the bare fiber segment 46 within the first bore segment 40.Such fiber insertion is indicated at step 112 of the process. Theoptical fiber stub 24 is inserted into the ferrule bore 34 through therear end 28 of the ferrule 22. During insertion, the optical fiber stub24 is oriented such that the bare fiber segment 46 leads the opticalfiber stub 24 through the ferrule 22. After insertion, an end portion ofthe bare fiber segment 46 projects outwardly from the end face 34 of theferrule 22. The epoxy delivery and fiber insertion steps can beautomated. During such steps, the ferrule can be held by the automatedferrule handler.

At step 114, the ferrule assembly 20 is cured (e.g., oven cured), cooledand cleaved. It is noted that the curing process is particularlyefficient because the ferrule 22 can be directly heated and the heatdoes not need to pass through a connector body or other structuresurrounding the ferrule 22. Similarly, the cooling process is efficientsince only the ferrule 22 and the optical fiber stub 24 need to becooled. Cleaving can be conducted using a laser or a mechanical cleavingtool. The curing, cooling and cleaving steps can be automated.

Once the optical fiber stub 24 has been cleaved adjacent the end face 30of the ferrule 22, the cleaved interface end 32 of the optical fiber 24can be polished as indicated at step 116. It will be appreciated thatthe polishing process can include multiple polishing steps usingdifferent polishing pads and polishing compounds having differentdegrees of abrasiveness. Because the ferrule assembly 20 is notconnected to an extended length of cable, downward vertical polishingpressure can be applied without side loading from a cable. The absenceof an extended length of cable coupled to the ferrule 22 also allows theferrule assembly 20 to be rotated about its axis 76 during the polishingprocess. In certain embodiments, the ferrule assembly 20 can be rotatedabout its axis 76 at a rate of at least 10 rotations per minute, or atleast 50 rotations per minute, or at least 100 rotations per minute, orat least 500 rotations per minute.

FIGS. 8 and 9 show the ferrule end face 30 and the interface end 32 ofthe optical fiber 24 being polished using a rotating polishing table 70that rotates about an axis 72. A polishing pad 74 can be provided on therotating polishing table 70. In other embodiments, rather than rotating,the polishing table 70 may oscillate, reciprocate, move along a randomorbit path, or otherwise move. Additionally, during the polishingprocess, it may be desirable to rotate the ferrule 22 about its axis ofrotation 76 as described above.

As shown at FIGS. 8 and 9, a mechanical polishing process is used topolish the end face 30 of the ferrule and the interface end 32 of theoptical fiber stub 24. In other embodiments, a laser can be used to bothcleave and polish/process the interface end 32 of the optical fiber stub24. When processing the end 32 of the optical fiber stub 24 with alaser, it may be desirable to rotate the ferrule 22 about its axis 76 asdescribed above.

The above-described polishing steps can be automated. During polishing,the ferrule 22 can be held by the automated ferrule handler. In certainembodiments, the automated handler can include a rotational drive 35 forrotating the ferrule 22 about its axis 76 during polishing or othersteps disclosed herein here rotation of the ferrule 22 about its centeraxis is desired.

During the polishing process, it is desirable to interrupt polishing andprovide tuning of the ferrule assembly 20 (see step 118). It will beappreciated that tuning is a process where an offset direction of thecore 47 is established and an indication of the core offset direction isprovided on the ferrule 22. The indication of the core offset directioncan include any number of techniques such as printing a mark on theferrule 22, etching a mark on the ferrule 22, or otherwise marking theferrule 22. The core offset direction is the direction in which the core47 is offset from a centerline (e.g., axis 76) of the ferrule 22.

As shown at FIG. 10, the ferrule assembly 20 can be tuned by shining alight 80 through a rear end of the optical fiber stub 24 such that thelight is conveyed through the optical fiber stub 24 and out theinterface end 32 of the optical fiber stub 24. A camera 82 or otherstructure can be used to view and monitor the light output through thefiber core 47 at the end 32 so as to determine the core position. Theferrule assembly 20 is then rotated about its axis 76 while the light 80continues to be directed through the optical fiber stub 24 and thecamera 82 continues to view the end 32 of the optical fiber stub 24. Asthe ferrule assembly 20 is rotated about its axis 76, the core 47 of theoptical fiber stub 24 changes elevations relative to a horizontal line H(see FIG. 11) that intersects the centerline 76 of the ferrule 22.

FIG. 12 is a graph illustrating the height of the core 47 relative tothe horizontal line H as the ferrule 22 is rotated about its centerlineaxis 76. As shown at FIG. 12, the maximum core height 89 is indicativeof an offset direction 91 of the core 47 relative to the axis 76 of theferrule assembly 20. The axis 76 of the ferrule assembly 20 is definedby the outer diameter of the ferrule 22. Once the core offset direction91 has been established, the ferrule 22 can be marked accordingly suchthat the offset direction can be identified at a later time in themanufacturing process. For example, as shown at FIG. 11, a marking 93 isprovided in direct alignment with the core offset direction 91. In otherembodiments, the marking could be offset 180° from the core offsetdirection 91 or at other locations on the ferrule 22. When the ferruleassembly 20 is later installed in a connector body, the marking 93 isused to orient the core offset a desired location relative to theconnector body. For example, in a preferred embodiment, the core offsetdirection 91 is oriented at the twelve o'clock position relative to theconnector body. The marking 93 can also be used to orient the coreoffset relative to a hub that is subsequently mounted on the ferrule 22.The hub can include a keying structure for ensuring that the ferrule ismounted at a desired rotational position within the connector body suchthat the core offset is oriented at a desired rotational positionrelative to the connector body.

Because the ferrule assembly 20 is tuned prior to insertion within aconnector body and/or prior to mounting the hub on the ferrule 22,tuning can be provided at an infinite number of increments (i.e., themarking location can be chosen from an infinite number ofrotational/circumferential positions about the centerline of theferrule) to provide precise alignment of the marking 93 with the coreoffset direction 91. In another embodiment, the marking location can bechosen from a discrete number of rotational/circumferential positionsabout the centerline of the ferrule, where the number of discreterotational/circumferential positions is at least 6, or at least 12, orat least 18, or at least 24, or at least 30. In other examples, theferrule assembly 20 is tuned after at least a portion of the hub ismounted on the ferrule and the hub can define a discrete number ofrotational/circumferential positions. In such examples, a core offsetmarking can be provided on the hub. The tuning step can be automated androtation of the ferrule 22 during tuning can be achieved by theautomated ferrule handler.

After tuning, the polishing process is completed at step 116 and variousinspections are conducted at step 118. The inspections can include acorporate workmanship standard inspection in which the end 32 of theoptical fiber stub 24 is inspected with a microscope to insure thatthere are no unacceptable scratches, pits or chips on the end face. Theend face 32 of the optical fiber stub 24 and the end face 30 of theferrule 22 can also be inspected and analyzed to insure the end facescomply with certain geometry specifications for the end faces. Finally,a continuity check can be conducted by which a light is shined throughthe optical fiber stub 24 to make sure the optical fiber stub 24 iscapable of transmitting light. After the continuity check has beencompleted, a dust cap can be installed on the ferrule 22 and the ferruleassembly 20 can be packaged at shown at step 120. The various stepsdescribed above can be automated.

FIGS. 13-15 illustrate a fiber optic cable and connector assembly 200 inaccordance with the principles of the present disclosure. The fiberoptic cable and connector assembly 200 includes a fiber optic connector202 having a connector body 204. The connector body has a front end 206and a back end 208. The ferrule assembly 20 is positioned at leastpartially within the connector body 204. Specifically, the ferruleassembly 20 is positioned with the ferrule 22 positioned adjacent to thefront end 206 of the connector body 204. The fiber optic connector 202further includes a boot 210 mounted adjacent the back end 208 of theconnector body 204. As used herein, the word “adjacent” means at ornear. In a preferred embodiment, the connector 202 is compatible withexisting connectors, fiber optic adapter, patch panels and fiber opticcables.

The fiber optic cable and connector assembly 200 further includes afiber optic cable 212 that extends through the boot 210. The fiber opticcable 212 includes a jacket 214 and an optical fiber 216 positionedwithin the jacket 214. The optical fiber 216 can be referred to as a“second optical fiber.” The optical fiber 216 is optically connected ata fusion splice 217 to the optical fiber 24 of the ferrule assembly 20.The fusion splice 217 is positioned at a splice location 218 spaced fromthe rear end 28 (i.e., the base) of the ferrule 22. In one embodiment,the splice location 218 is within the connector body 204 and ispositioned no more than 20 mm from the rear end 28 of the ferrule 22.The fusion splice 217 is preferably a factory fusion splice. A “factoryfusion splice” is a splice performed at a manufacturing facility as partof a manufacturing process. In one embodiment, the fiber optic connector202 fully complies with Telcordia GR-326 or similar stringent industryor customer specifications. In other examples, the splice can be a fieldsplice.

Referring to FIG. 15, the connector body 204 includes a front piece 220and a rear piece 222. The front piece 220 forms a front interface end ofthe fiber optic connector 202 and the rear piece 222 is configured toallow strength members 224 (e.g., aramid yarn, fiberglass or otherstrength members capable of providing tensile reinforcement to the fiberoptic cable 212) of the fiber optic cable 212 are anchored. In certainembodiments, the strength members 224 can be secured to the rear piece222 of the connector body 204 with a mechanical retainer such as a crimpsleeve. In other embodiments, adhesive or other means can be used tosecure the strength members 224 to the connector body 204.

Still referring to FIG. 15, the front and rear pieces 220, 222 of theconnector body 204 interconnect together by a connection such as asnap-fit connection, an adhesive connection or other type of connection.When the front and rear pieces 220, 222 are connected together, a spring228 and a hub 230 are captured between the front and rear pieces 220,222. The hub 230 is secured over the rear end 28 of the ferrule 22. Thehub 230 also covers the splice location 218 such that the fusion splice217 is located within the hub 230. In the depicted embodiment, anintermediate layer 232 (e.g., a coating layer, an over mold layer, orother layer) is provided between the fusion splice 217 and the hub 230.The spring 228 is captured within a spring pocket 229 defined by therear piece 222 and functions to bias the hub 230 and the ferruleassembly 20 which is carried with the hub 230 in a forward directionrelative to the connector body 204. The hub 230 is a structure securedon the ferrule 22 such that the ferrule 22 and the hub 230 move togetheras a unit. In certain embodiments, the hub 230 provides structureagainst which the bias of the spring 228 can be applied to bias the hub230 and the ferrule 22 forwardly relative to the connector body 204. Thehub 230 also includes structure that interferes with an internalstructure (e.g., a stop) of the connector body 204 to limit the forwardmovement of the ferrule 22 and to prevent the ferrule 22 from beingpushed out of the front of the connector body 204 by the spring 228. Thehub 230 and the splice location 218 can be positioned within the springpocket 229. The boot 210, the rear piece 222 and the spring 228 all canhave internal dimensions (e.g., inner diameters) larger than an outerdimension (e.g., an outer diameter) of the cable 212 such that duringassembly/manufacturing the boot 210, the rear piece 222 and the spring228 can be slid back over the jacket 212 to provide space/clearance forsplicing and application of the hub over the spice 217.

In the depicted embodiment, the fiber optic connector 202 is shown as astandard SC-type connector. As such, the fiber optic connector 202 isadapted to be received within an SC-type fiber optic adapter that isused to couple two of the fiber optic connectors together to provide anoptical connection there between. The fiber optic connector 202 includesa release sleeve 236 that is slidably mounted on the connector body 204.When the fiber optic connector 202 is inserted within a fiber opticadapter, shoulders of the connector body 204 are engaged by latches ofthe fiber optic adapter to retain the fiber optic connector 202 withinthe fiber optic adapter. To release the fiber optic connector 202 fromthe fiber optic adapter, the release sleeve 236 is slid rearwardlyrelative to the connector body 204 thereby causing the latches of thefiber optic adapter to disengage from the shoulders of the connectorbody 204 such that the fiber optic connector 202 can be withdrawn fromthe fiber optic adapter. An example fiber optic adapter is disclosed atU.S. Pat. No. 5,317,663, which is hereby incorporated by reference inits entirety.

In a preferred embodiment, the splice location 218 is relatively closeto the rear end 28 of the ferrule 22. For example, in one embodiment,the splice location 218 is no more than 15 mm from the ferrule 22. Inanother embodiment, the splice location 218 is no more than 10 mm fromthe ferrule 22. In still another embodiment, the splice location 218 isno more than 5 mm from the ferrule 22. In further embodiments, thesplice location is spaced 1-20 mm from the ferrule 22, or 1-15 mm fromthe ferrule 22 or spaced 1-10 mm from the ferrule 22, or 1-5 mm from theferrule 22, or 2-10 mm from the ferrule 22, or 2-5 mm from the ferrule22, or 1-3 mm from the ferrule 22, or less than 4 mm from the ferrule22, or less than 3 mm from the ferrule 22, or 1-4 mm from the ferrule22, or 2-3 mm from the ferrule 22.

To the extent that in some embodiments of the present disclosure a hubmay not be provided, the splice location 218 (i.e., the interfacebetween the two optical fibers 24, 216) is preferably located in theregion that would normally be occupied by a hub. In certain embodiments,the splice location is provided between the base of the ferrule 22 andthe rear end of the spring 228. In certain embodiments, the splicelocation 218 is within the spring chamber 229. In certain embodiments,the spring 228 biases the ferule 20 toward a forward-most position(i.e., a distal-most position or non-connected position) and during aconnection with another connector the spring 228 allows the ferrule 22to move rearwardly from the forward-most position, against the bias ofthe spring 228, to a rearward position (i.e., proximal position orconnected positioned). In certain embodiments, the splice location 218is positioned between forward and rearward ends 228 a, 228 b of thespring 228 when the ferrule is in the forward-most position, and is alsopositioned between the forward and rearward ends 228 a, 228 b of thespring 228 when the ferrule 22 is in the rearward position.

In certain embodiments, the hub 230 has a polymeric construction thathas been over molded over the rear end of the ferrule 22 and over thesplice location 218. By protecting the fusion splice 217 within the hub230 at a location in close proximity to the ferrule 22, it is possibleto manufacture a fiber optic connector that is relatively short inlength. In a preferred embodiment, the fiber optic connector 202 has alength L3 that is less than 57 mm. It will be appreciated that thelength L3 of the fiber optic connector 202 is measured from the frontend 26 of the ferrule 22 to a rear end 240 of the boot 210. In certainembodiments, a portion 231 of the hub 230 that extends rearward of theferrule 22 has a length L4 that is shorter than the length L1 of theferrule 22. In certain examples, the splice location 218 is within 5 mmof the rear end of the ferrule 22. Providing the splice location 218within 5 mm of the rear end of the ferrule 22 assists in designing thefiber optic connector in compliance with standard industry or customerside load and connector length specifications (e.g., GR-326 side loadand length requirements).

The boot 210 is shown press-fit over the rear piece 222 of the connectorbody 204. Specifically, the boot 210 is press-fit over the locationwhere the strength members 224 are attached to the connector body 204.It will be appreciated that the boot 210 has a tapered, flexibleconfiguration that provides the optical fiber 216 with bend radiusprotection when a side load is applied to the fiber optic connector 202through the fiber optic cable 212.

In one embodiment, the fusion splice 217 is a factory fusion splicehaving a splice related insertion loss of 0.1 decibels or less, 0.05decibels or less, or 0.02 decibels or less in the 1260 nanometer to 1630nanometer signal wavelength range. Furthermore, in preparing the opticalfibers for the fusion splice 217, an active alignment system can beutilized to accurately align the optical fibers 216, 24. Example activealignment systems are sold by Sumitomo, Furukawa, Vytran, 3SAE, andFujikura. In certain embodiments, the active alignment system can ensurethat the centers of the cores of the optical fibers 216, 24 beingspliced are offset by no more than 0.01 microns by the alignment systemprior to splicing. The alignment system can utilize cameras that viewthe cores of the optical fibers 216, 24 along viewing lines that areperpendicular to one another (e.g., a top view and a side view).

As described above, in certain embodiments, the optical fiber stub 24can be manufactured using a precision fiber having tightly tolerancedparameters such as core to cladding concentricity and cladding outerdiameter variation. In this regard, in certain embodiments, the opticalfiber stub 24 can be different (e.g., can have a different construction,different mechanical characteristics, different physical attributes,different optical performance characteristics, different degrees ofprecision, etc.) than the optical fiber 216 of the fiber optic cable.For example, the optical fiber stub 24 can be a more preciselymanufactured optical fiber than the optical fiber 216 of the fiber opticcable 212 (i.e., the stub fiber is manufactured according to tightertolerances than the cable optical fiber 216). For example, in certainembodiments, the optical fiber stub 24 can have better average core tocladding concentricity than the optical fiber 216. Also, the outerdiameter of the cladding of the optical fiber stub 24 can be moreprecisely toleranced that the outer diameter of the cladding of theoptical fiber 216. Further, the optical fiber stub 24 can have adifferent (e.g., lower) fiber cut-off wavelength than the optical fiber216. Moreover, the optical fiber stub 24 can have different claddingmode suppression characteristics as compared to the optical fiber 216.For example, as compared to the optical fiber 216, the optical fiberstub 24 can have a construction adapted to provide enhanced claddingmode suppression for suppressing modal interference. Example opticalfibers having constructions adapted to reduce/suppress modalinterference are disclosed at U.S. Pat. Nos. 6,498,888; 5,241,613; and4,877,306, which are hereby incorporated by reference in theirentireties.

It is well known in the art that splices can introduce losses (e.g.,insert loss, return loss). However, the fiber optic cable and connectorassembly 200 of the present disclosure includes various features thatprovide excellent performance despite the presence of an internalsplice. Such features include: a) precise core-to-core alignment of thespliced optical fibers; b) precise centering of the optical fiber stub24 within the ferrule bore 34, precise tuning of the core offsetdirection within the connector body, and precise centering of theferrule bore 34 within the ferrule 22.

In certain examples, the fiber optic connector 202 can be in fullcompliance with the requirements of Telcordia GR-326. Specific sectionsof Telcordia GR-326 in which the fiber optic connector 202 can be incompliance include sections pertaining to transmission with appliedload, installation tests, and the post-condensation thermal cycle test.

FIG. 16 shows a process for manufacturing a patch cord formed bymounting fiber optic connectors 202 on opposite ends of the fiber opticcable 212. At step 300 of the method, the fiber optic cable 212 iscoiled and the components of the fiber optic connectors 202 are staged.Next, at step 302, the ends of the jacket 214 of the fiber optic cable212 are then cut and slit, and the strength layer 224 is trimmed. As soprepared, end portions of the optical fiber 216 extend outwardly fromeach end of the jacket 214. The end portions of the optical fiber 216are then stripped, cleaned and cleaved (e.g., laser cleaved) (see step304). During stripping, cleaning and cleaving, the end portions of theoptical fiber 216 can be gripped in a holder 217 (e.g., a holding clipor other structure) (see FIG. 18).

At step 306, ferrule assemblies 20 are fed (e.g., bowl fed) to a holder240 or holders which grip/hold the ferrule 22. An example holder 240 isshown at FIG. 17. In some examples, the ferrules 22 are oriented withinthe holders 240 with the tuning marks 93 at the twelve o'clock positionso that the ferrule assemblies 20 can be subsequently loaded into theircorresponding connector bodies 204 at the twelve o'clock position. Inthis way, it is ensured that the core offset direction is oriented atthe uppermost position/sector of each connector. While the twelveo'clock position is preferred, the core offset direction can beestablished within the connector body at other rotational positions aswell.

While each ferrule 22 is held by the holder 240, the free end of theoptical fiber stub 24 is stripped, cleaned (e.g., arc cleaned) andcleaved (e.g., laser cleaved) (see step 308). It will be appreciatedthat ferrule assemblies 20 are prepared for each end of the patch cable.

Once the fibers have been stripped, cleaned and cleaved, the opticalfiber stub 24 of each ferrule assembly 20 is coarsely aligned with acorresponding end portion of optical fiber 216 (see FIG. 19), and thenprecisely aligned (see FIG. 20). Precise alignment of the optical fiberscan be accomplished using an active alignment device. In using theactive alignment device, the fiber 216 is held within the holders 217with an end portion of the fiber 216 projecting outwardly from one endof the holder 217 (as shown at FIGS. 20-23, the cable 212 projectingfrom the opposite end of the holder 217 has been omitted). Also, theferrule 22 is held within a pocket of the holder 240 while the fiber 24projects from the base of the ferrule 222 and is not contacted directlyby the holder 240 or any other structure. The holder 240 can include aclip or other structure having two or more pieces that clamp and holdthe ferrule 22 during active alignment of the fibers 216, 24. The pocketof the holder 240 can include an internal structure (e.g., a V-groove,semi-circular groove, etc. for aligning/positioning the ferrule 22). Theend portions of the fibers are preferable unsupported (e.g., not indirect contact with a structure such as a v-groove). In one example, thefiber 24 projects less than 5 mm from the base end of the ferrule 22.This relatively short length facilitates the active alignment process.In certain examples, the center axis of the fiber 24 is angled no morethan 0.1 degrees relative to the center line of the ferrule. This alsoassists the active alignment process. While ideally there is no angularoffset between the center axis of the fiber 24 and the ferrule 22, theshort stub length of the fiber 24 assist in minimizing the effect duringactive alignment of any angular offset that may exist. Robotics arepreferably used to manipulate the holders 240, 217 to achieve axialalignment between the cores of the fibers 24, 216. Because alignmentdoes not rely on contacting extended lengths of the fibers 24, 216 withalignment structure such as v-grooves, the splice location can beprovided in close proximity to the base of the ferrule 22 (e.g., within5 mm of the base). In certain embodiments, only splices in which thecenters of the cores of the optical fibers 216, 24 being spliced areoffset by no more than 0.01 microns are acceptable, and splices fallingoutside of this parameter are rejected. In other embodiments, theaverage core offset for fibers spliced by the process is less than 0.01microns.

After precise axial alignment has been achieved, a shielding unit 250 islowered over the splice location 218 and a fusion splice machine 251(e.g., an arc treatment machine) is used to fuse the optical fibers 24,216 together. The shielding unit 250 includes shielding portions forshielding the ferrule 22 and coated portions of the optical fibers 24,216 intended to be spliced together. The shielding structure 250 canhave a ceramic construction, Polyether ether ketone (PEEK) construction,another heat resistant plastic construction or other type of heatresistant construction. Preferably, the shielding structure 250 includesa gap g through which an arc or other energy source from the fusionsplice machine 251 can pass to fusion splice the optical fibers 24, 216together. Preferably the gap g is 1-3 mm, or 2-2.5 mm. FIG. 20 shows theshielding structure 250 in the raised orientation and FIG. 21 shows theshielding structure in a shielding position. The shielding structure caninclude side walls 253 that protect the sides of the ferrule 22 andextend along the lengths of optical fibers 24, 216, and cross-walls 255that extend between the side walls 253. The cross-walls 255 extendacross to the optical fibers 24, 216 (e.g., transverse to the opticfibers 24, 216) and include slots 257 for receiving the optical fibers24, 216. The side walls 253 also protect the portions of the fibers 24,216 adjacent the splice location and the holders 214, 240. Thecross-walls 255 protect the fibers 24, 216, the rear end 28 of theferrule 22 and the holders 214, 240. A bridge section extends across thegap g between the cross-walls 255. Step 310 of FIG. 16 is representativeof the alignment, shielding and fusion splicing operations.

After the fusion splice has been completed, a protective layer 232 canbe placed, applied or otherwise provided over the optical fibers 24, 216in the region between the rear end 28 of the ferrule 22 and abuffered/coated portion of the optical fiber 216. In one example, theprotective layer 232 extends completely from the rear end 28 of theferrule 22 to a coated and buffered portion of the optical fiber 216. Asdepicted, the coated and buffered portion of the optical fiber 216includes coatings in the form of a 220-260 micron acrylate layers whichcover the glass portion of the optical fiber, and a buffer layer 221(e.g., a loose or tight buffer tube) having an outer diameter rangingfrom 500-1,100 microns. At FIG. 22, the protective layer 232 is shownextending over the splice location 218 completely from the rear end 28of the ferrule 22 to the buffer layer of the optical fiber 216. In oneembodiment, the protective layer 232 is generally cylindrical (see FIG.15) and has a diameter slightly larger than the buffer layer andgenerally the same as a major diameter of the conical transition 39 ofthe ferrule bore 34. In other embodiments, the protective layer 232 canhave a truncated conical configuration (see FIG. 22) with a majordiameter generally equal to the outer diameter of the ferrule 22 and aminor diameter generally equal to the outer diameter of the buffer layerof the optical fiber 216. It will be appreciated that the protectivelayer 232 can be applied using an over molding technique. Alternatively,coating, spraying, laminating or other techniques can be used to applythe protective layer.

In certain embodiments, the protective layer 232 is made of a materialthat is softer (e.g., has a lower hardness) than the material used tomanufacture the hub 230. In certain embodiments, the unstripped portionof the optical fiber 216 has an inner coating layer that surrounds thecladding layer, and the protective layer 232 has mechanical attributessuch as softness/hardness that substantially match or are comparable tothe mechanical attributes of the inner coating layer of the unstrippedportion of the optical fiber 216. In certain embodiments, the protectivelayer 232 can be made of a thermoplastic material, a thermoset material(a material where cross-linking is established during heat curing),other types of cross-linked materials or other materials. Examplematerials include acrylates, epoxies, urethanes, silicones and othermaterials.

At least some of the materials can be UV curable (i.e., the materialscure when exposed to ultraviolet radiation/light). One example materialincludes a UV curable splicing compound such as DSM-200 which is sold byDSM Desotech, Inc. of Elgin Ill. In certain embodiments, an injectionmolding process (e.g., a thermoplastic injection molding process) can beused to apply and form the protective layer 232 about the splicelocation 218.

Once the protective layer 232 has been applied and cured, the hub 230 ispreferably over molded over the protective layer 232 as shown at FIG.23. The hub 230 is preferably over molded over the rear end 28 of theferrule 22 and also over the splice location 218. FIG. 24 shows a moldassembly 400 mold pieces 400 a, 400 b having an inner shape that matchesthe outer shape of the hub 230. The mold assembly 410 shown in FIGS.75-81, discussed below, may also be used to form the hub 230.Preferably, a polymeric material is injected from an injection machine403 into a cavity 401 defined by the mold pieces 400 a, 400 b to overmold the polymeric material over the splice location 218 and the rearend 28 of the ferrule 22. In certain embodiments, the hub 230 is moldedby injecting a UV curable material into the mold, and the mold pieces400 a, 400 b are made of a UV transmissive material (e.g., Teflon) suchthat UV light/radiation can be transmitted through the mold pieces 400a, 400 b for curing the hub 230 within the mold.

Referring back to FIG. 15, the hub 230 is shaped to include a flange 260that engages the spring 228. Additionally, the hub 230 is configured tosupport the rear end 28 of the ferrule 22 within the connector body 204.Furthermore, a forward end or flange 263 of the hub 230 is configured toengage a shoulder 261 within the connector body 204 to halt forwardmovement of the ferrule assembly 20 caused by the forward bias providedby the spring 228. In this way, the flange 263 functions to retain theferrule 22 within the connector body 202. FIG. 25 shows the ferruleassembly 20 after the hub 230 has been over molded over the rear end 28of the ferrule 22, over the splice location 218 and over a bufferedportion of the optical fiber 216 of the fiber optic cable 212. Step 312of FIG. 16 is representative of the over molding operations.

In certain embodiments, the hub 230 can be made of a thermoplasticmaterial, a thermoset material (a material where cross-linking isestablished during heat curing), other types of cross-linked materials,or other materials. Example materials include acrylates, epoxies,urethanes, silicones and other materials. At least some of the materialscan be UV curable (i.e., the materials cure when exposed to ultravioletradiation/light). As described above, in certain embodiments, aninjection molding process (e.g., a thermoplastic injection moldingprocess) can be used to apply and form the hub 230 about the splicelocation 218 and ferrule 22. In certain embodiments, a hot melt materialcan be injected into the mold to form the hub 230. The use of hot meltmaterials (e.g., hot melt thermoplastic materials) and/or UV curablematerials allows the hub over molding process to be conducted atrelatively low pressures (e.g., less than 1000 pounds per square inch(psi)) and at relatively low temperatures (e.g., less than 300 degreesCelsius). In certain examples, curing can take place at temperaturesless than 200 degrees Celsius, or less than 100 degrees Celsius, or atroom temperature, and at pressures less than 100 psi or at pressuresless than 10 or 5 psi.

After the hubs 230 have been over molded at each end of the fiber opticcable 212, the other components of the fiber optic connectors 202 areassembled over the ferrule assembly 20 and the hub 230 (see step 314 atFIG. 16). Additionally, the strength members of the fiber optic cable212 are attached to the rear ends of the connector bodies 204 of thefiber optic connectors 202. A continuity check can be conducted for thepatch cable and dust caps are positioned over the ferrules 22 (see step316 at FIG. 16). Finally, the patch cords are packaged and labeled (seestep 318 of FIG. 16). It will be appreciated that any and/or all of theabove connector manufacturing steps can be automated. Robotics canimprove the consistency and quality of the connectorization process andautomation can assist in lowering labor related costs.

Various additional fiber optic connector embodiments are describedbelow. It will be appreciated that the various materials, properties,dimensions and other features described above with respect to componentssuch as the ferrule, the optical fibers, the hub, connector body and theboot are also applicable to like components described below.

FIGS. 26, 27 and 27A illustrate another fiber optic cable and connectorassembly 200 a in accordance with the principles of the presentdisclosure. The fiber optic cable and connector assembly 200 a includesa fiber optic connector 202 a having a connector body 204 a in which aferrule 22 a is mounted. The ferrule 22 a supports an optical fiber stub24 a having a bare optical fiber segment 46 a spliced to a bare fibersegment 291 a of an optical fiber 216 a of an optical cable. The opticalfiber 216 a includes a coated portion 293 a. A loose buffer tube 221 asurrounds and protects at least a portion of the coated portion 293 a ofthe optical fiber 216 a. The bare fiber segment 46 a is spliced to thebare fiber segment 291 a at a splice location 218 a. A generallycylindrical protective layer 232 a is coated or overmolded over thesplice location 218 a. More specifically, the protective layer 232 a isshown extending from a rearward end of the ferrule 22 a to a forward endof the buffer tube 221 a. The protective layer 232 a fully encapsulatesthe bare fiber segments 46 a, 291 a and also encapsulates a portion of acoated fiber segment 48 a of the optical fiber stub 24 a and a portionof the coated portion 293 a of the optical fiber 216 a. The protectivelayer 232 a further encapsulates the forward end of the loose buffertube 221 a. In certain embodiments, some of the material forming theprotective layer 232 a flows around the exterior of the buffer tube 221a and also flows inside the buffer tube 221 a between the interior ofthe buffer tube 221 a and the coated portion 293 a of the optical fiber216 a. A hub 230 a is over molded around the rearward end of the ferrule22 and encapsulates and protects the protective layer 232 a as well asthe splice location 218 a within the protective layer 232 a. The hub 230a is bonded or otherwise secured/attached to the ferrule 22 a. A spring228 a biases the hub 230 a and the ferrule 222 a in a forward direction.As shown at FIG. 27, the hub 232 a extends from the rearward end of theferrule 22 a to the loose buffer tube 221 a and fully encapsulates theprotective layer 232 a. Additionally, a rearward portion of the hub 232a surrounds and bonds to an exterior surface of the buffer tube 221 a toprevent the buffer tube 221 a from being pulled from the connector.Because both the protective layer 232 a and the hub 230 a are bonded orotherwise attached to the buffer tube 221 a, the buffer tube 221 a hasenhanced pull-out characteristics. Such characteristics are furtherenhanced if the protective layer 232 a is bonded to both the outside andthe inside of the buffer tube 221 a.

In the embodiment of FIG. 27, the portion of the hub 230 a attached tothe outer surface of the buffer tube 221 a has an axial length that islonger than a corresponding axial length of the portion of theprotective layer 232 a that is attached to the buffer tube 221 a. FIGS.28, 29 and 29A show another fiber optic cable and connector assembly 200b having the same basic construction as the fiber optic cable andconnector assembly 200 a except a protective layer 232 b has beenlengthened to increase the contact length between the protective layer232 b and a buffer tube 221 b, and a hub 230 b has been modified toaccommodate the lengthened protective layer 232 b. In this way, theportion of the protective layer 232 b attached to the buffer tube 221 bis longer than the portion of the hub 232 b that engages and is bondedto or attached to the buffer tube 221 b. The embodiment of FIGS. 28, 29and 29 a is particularly advantageous for applications where theprotective layer 232 has better adhesion characteristics with respect tothe buffer tube 221 as compared to the material of the hub 230 b. Incontrast, the embodiment of FIGS. 27, 28 and 28A is preferred forembodiments where the material of the hub 230 a has enhanced bondingcharacteristics with respect to the buffer tube 221 a as compared to thematerial of the protective layer 232 a. In both of the embodiments, therear portion of the hub engages and circumferentially surrounds (i.e.,shuts-off against) the buffer tube.

FIGS. 30, 31 and 31A show a further fiber optic cable and connectorassembly 200 c in accordance with the principles of the presentdisclosure. The fiber optic cable end connector assembly 200 c hasstructure adapted to enhance retention of a buffer tube 221 c within afiber optic connector 202 c. As shown at FIGS. 31 and 31A, the fiberoptic connector 202 c includes a crimp ring 295 mechanically crimpedadjacent a forward end of the buffer tube 221 c. The crimp ring 295includes a recess or receptacle in the form of an annular groove 296that extends around a perimeter of the crimp ring 295. The fiber opticconnector 202 c further includes a hub 230 c over molded over the crimpring 295 and the forward end of the buffer tube 221 c. The hub 230 cincludes an annular projection 297 that projects radially inwardly intothe annular groove 296 of the crimp ring 295. In this way, a mechanicalinterlock exists between the hub 230 c and the crimp ring 295. Themechanical interlock resists relative axial movement between the crimpring 295. The crimp ring has a forward end that abuts against aprotective layer 232 c that protects a splice location 218 c between anoptical fiber stub 24 c and an optical fiber 216. The optical fiber stub24 c has forward ends supported in a ferrule 22 c and rearward endportions that project rearwardly from the ferrule 22 c. The opticalfiber 216 c corresponds to a fiber optic cable. The protective layer 232c protects a bare fiber segment 291 c and a coated portion 293 c of theoptical fiber 216 c as well as a coated fiber segment 48 c and a barefiber segment 46 c of the optical fiber stub 24 c. The hub 230 csurrounds and is coupled to (i.e., boded to, affixed to, attached to) arearward end of the ferrule 22 c and fully encloses the protective layer232 c, the forward end of the buffer tube 221 c and the crimp ring 295.A rearward end of the hub 230 c forms an annular buffer tube contactsurface that shuts off against an exterior of the buffer tube 221 c at alocation rearward of the crimp ring 295.

In the embodiments of FIGS. 27, 29 and 31, the hubs have rear portionsthat circumferentially engage their corresponding buffer tubes. Thus,the molds used to form the hubs shut off on the buffer tubes. Incontrast, FIGS. 32, 33 and 33 a show a further fiber optic cable andconnector assembly 200 d in accordance with the principles of thepresent disclosure where a hub 230 d of a fiber optic connector 202 ddoes not engage a corresponding buffer tube 221 d of the fiber opticcable and connector assembly 200 d. Instead, the fiber optic cable andconnector assembly 200 d includes an elongated protective layer 232 dthat encapsulates a forward end of the buffer tube 221 d and alsoencapsulates the splice location 218 d. The protective layer 232 ddefines an annular groove 298 that extends around its perimeter at alocation adjacent the splice location 218 d. The hub 230 d is overmolded over the protective layer 232 d and includes an annularprojection 299 that fills and fits within the annular groove 298. Thisway, a mechanical interlock is formed between the protection layer 232 dand the hub 230 d to prevent a relative axial movement between the hub230 d and the protective layer 232 d. The protective layer 232 d ispreferably affixed or otherwise bonded to the exterior surface of thebuffer tube 221 d and also can fill a portion of the buffer tube 221 dso as to bond with an interior surface of the buffer tube 221 d. Theprotective layer 232 d projects rearwardly beyond a rearward end of thehub 230 d. In this way, the rearward end of the hub 230 dcircumferentially surrounds and contacts the protective layer 232 d butdoes not contact the buffer tube 221 d. Thus, a mold for forming the hub230 d is configured to shut-off around the protective layer 232 d ratherthan the buffer tube 221 d. In other embodiments more than one innerlock structure can be provided between the hub 230 d and the protectivelayer 232 d. Additionally, the inner lock structures can be provided atdifferent locations along the length of the protective layer 232 d. Theprotective layer 232 d has an outer diameter larger than an outerdiameter of the buffer tube 221 d.

FIGS. 34, 35 and 35 a show another fiber optic cable and connectorassembly 200 e in accordance with the principles of the presentdisclosure. The fiber optic cable and connector assembly 200 e includesa fiber optic connector 202 e having a ferrule 22 e supporting anoptical fiber stub 24 e. The fiber optic cable and connector assembly200 e also includes an optical fiber 216 e spliced to the optical fiberstub 24 e at a splice location 218 e. The optical fiber 216 correspondsto an optical cable having a buffer tube 221 e. The optical fiber stub24 e includes a coated fiber segment 48 e and a bare fiber segment 46 c(i.e., a bare glass segment). The optical fiber 216 includes a barefiber segment 291 e and a coated portion 293 e. A protective layer 232 eextends from a rear end of the ferrule 22 e to a forward end of thebuffer tube 221 e. In the depicted embodiment, the protective layer 232e is generally cylindrical and has a maximum outer diameter that issmaller than an inner diameter of the buffer tube 221 e. The protectivelayer 232 e protects the splice location 218 e and the bare fibersegments 46 e and 291 e. The protective layer 232 e also encapsulatesportions of the coated fiber segment 48 e and the coated portion 293 e.A hub 230 e is over molded over the rear end of the ferrule 22 e, andover the forward end of the buffer tube 221 e. The protective layer 232e is fully enclosed or encapsulated within the hub 230 e. A mold used toform the hub 230 e closes on the buffer tube 221 e. This way, the rearportion of the hub 230 e circumferentially surrounds and is affixed toan outer surface of the buffer tube 221 e. A front portion of the hub230 e circumferentially surrounds and is coupled to the rear end of theferrule 22 e.

FIGS. 36-40 show a sequence for splicing an optical fiber stub 24 fsupported by a ferrule 22 f to an optical fiber 216 f of a fiber opticcable. The optical fiber stub 24 f includes a bare fiber segment 46 fand a coated fiber segment 48 f. The optical fiber 216 f includes a barefiber segment 291 f and a coated portion 293 f. The fiber optic cablealso includes a buffer tube 221 f that surrounds the coated portion 293f of the optical fiber 216 f. FIG. 36 shows the optical fiber 216 fcoaxially aligned with the optical fiber stub 24 f in preparation forsplicing. FIG. 37 shows the optical fiber stub 24 f spliced the opticalfiber 216 f. FIG. 38 shows a protective layer 232 f over molded orotherwise applied over a splice location 218 f between the optical fiber216 f and the optical fiber stub 24 f. The protective layer 232 fextends from a rearward end of the ferrule 22 f to a forward end of thebuffer tube 221 f. FIG. 39 shows a hub frame 300 (e.g., a case orframework) mounted over the rearward end of the ferrule 22 f and theforward end of the protective layer 232 f. The hub frame 300 ispreferably a pre-molded part that can be inserted over the ferrule 22 f.In certain embodiments, the hub frame 300 is manufactured of arelatively hard plastic material such as a polyamide material. As shownat FIG. 39, the hub frame 300 includes a forward ring 302 that mountsover the ferrule 22 f and a rearward ring 304 positioned over theprotective layer 232 f. A plurality of axial ribs 306 connect theforward ring 302 to the rearward ring 304. An inner diameter of theforward ring 302 preferably closely matches the size of the outerdiameter of the ferrule 22 f. A front end of the forward ring 302 caninclude a plurality of chamfered surfaces 308 adapted for seating withina connector body when the assembly is spring biased to a forwardposition within a connector. A plurality of openings 310 are definedbetween the axial ribs 206. For example, in the depicted embodiment, twoaxial ribs 206 spaced about 180° apart from one another are providedbetween the forward and rearward rings 302, 304. In other embodiments,more than two axial ribs 306 can be provided. The rearward ring 304 hasan inner diameter that is substantially larger than an outer diameter ofthe protective layer 232 f. In this way, an annular gap 312 is definedbetween the inner surface of the rearward ring 304 and the outer surfaceof the protective layer 232 f. The hub frame 300 can be made of amaterial that is harder and more robust that the material used to form arear portion of the hub. The hub frame 300 can be over molded on theferrule 22 f and can include an inner portion that fills or fits withina slot/recess 23 f of the ferrule 22 f to enhance retention of the hubframe 300 on the ferrule 22 f. The hub frame 300 can be over moldedusing an over molding process having higher process temperatures andpressures than an over molding process used to form a portion of the hub(e.g., hub portion 314) that covers the splice location. In this way,the hub is provided with a robust construction without exposing thesplice location to high processing temperatures and pressures.

After the hub frame 300 has been mounted over the ferrule 22 f as shownat FIG. 39, an over molded hub portion 314 can be over molded within andover the hub frame 300 to form a composite hub 230 f that is coupled tothe ferrule 22 f and contains the splice location 218 f. The over moldedportion 314 preferably fills void regions between the axial ribs 306 andalso fills the annular gap 312 between the rearward ring 304 and theprotective layer 232 f. In the depicted embodiment, the over molded hubportion 314 completely encapsulates the protective layer 232 f andincludes a rearward portion that closes around the buffer tube 221 f.The hub frame 300 and the over molded hub portion 314 cooperate todefine the composite hub 230 f that is anchored to the ferrule 22 f. Theover molded hub portion flows into the gaps between the annular ribs 306of the hub frame 300 and bonds to an exterior surface of the ferrule andfunctions to lock the hub frame 300 in place relative to the ferrule 22f. The axial ribs 306 are shown embedded within the over molded hubportion 314 and a portion of the over molded hub portion forms a ring316 that surrounds the axial ribs 306. The ring 316 abuts against abackside of the forward ring 302 and has an exterior surface that isgenerally flush with an exterior surface of the forward ring 302. Thefront end of the forward ring 302 is not covered by the over moldedportion 314. In this way, the forward end of the forward ring 302 formsa front nose of the composite hub 230 f.

It will be appreciated that the composite hub 230 f can be used in anyof the fiber optic connectors in accordance with the principles of thepresent disclosure. Additionally, in certain embodiments, the overmolded hub portion 314 is formed of a hot melt adhesive or othermaterial that can be applied and cured at relatively low moldingtemperatures and pressures. In certain embodiments, the overmolded hubportion 314 is made of a material having different material propertiesthan the material of the hub frame 300. For example, the overmolded hubportion 314 can be softer or more resilient than the hub frame 300. Thecomposite nature of the hub 230 f simplifies the molding operation.

The composite construction of the composite hub 230 f relies on the hubframe 300 to provide mechanical strength and precision. The compositeconstruction of the composite hub 230 f relies on the over molded hubportion 314 for securement of the composite hub 230 f to the ferrule 22f, for securement of the composite hub 230 f to the buffer tube 221 fand for providing additional protection with respect to the splicelocation 218 f and the bare fiber segments 46 f, 291 f.

It will be appreciated that various aspects of the present disclosureare also applicable to multi-fiber connectors. For example, FIG. 41shows a multi-fiber ferrule 422 supporting a plurality of optical fiberstub having a plurality of optical fibers 424. The ferrule 422 caninclude openings 427 in which alignment pins can be mounted to configurethe ferrule 422 as a male component. The optical fibers 424 arepreferably aligned along a row within the ferrule 422 and have end facesthat are polished and accessible at a forward end 426 of the ferrule422. Rear portions 438 of the optical fibers 424 project rearwardly froma rear end 428 of the ferrule 422. Similar to previous embodiments, theoptical fibers 424 can be precision optical fibers having differentproperties or characteristics than the optical fibers of the fiber opticcable to which the optical fiber stub is to be spliced.

In certain embodiments, the optical fibers 424 of the optical fiber stubare spliced to the optical fibers of the cable at a location in closeproximity to the rear end 428 of the ferrule 422. For example, in oneembodiment, the splice location is within 10 millimeters of the rear end428 of the ferrule 422. In other embodiments, the splice location iswithin 5 millimeters of the rear end of 428 of the ferrule 422. In stillother embodiments, the splice location is in the range of 2-5millimeters of the rear end 428 of the ferrule 422.

FIG. 42 shows the ferrule 422 mounted within a multi-fiber fiber opticconnector 430. The connector 430 includes a connector body 432 having afront piece 432 a and a rear piece 432 b. A boot 434 is mounted to arear end of the rear piece 432 b of the connector body 432. The frontend 426 of the ferrule 422 is accessible at the front end of theconnector body 432. A removable dust cap 435 is shown mounted over thefront end 426 of the ferrule 422. A release sleeve 437 is mounted overthe connector body 432. A spring 439 biases the ferrule 422 in a forwarddirection. To use the fiber optic connector 430, the dust cap 435 isremoved thereby allowing the front end of the connector to be insertedwithin a corresponding fiber optic adapter (e.g., an MPO adapter). As isknown in the art, the fiber optic connector 430 (e.g., an MPO connector)snaps within the fiber optic adapter. By pulling back on the releasesleeve 437, the fiber optic connector 430 can be released from the fiberoptic adapter.

FIGS. 43-48 show a sequence of steps for preparing a multi-fiber fiberoptic cable 440 to be spliced to the optical fibers 424 of the ferrule422 of FIG. 41. The multi-fiber cable 440 can include a plurality ofoptical fibers 442 positioned within a jacket 444. A strength layer 446for providing tensile reinforcement to the cable 440 can be positionedbetween the jacket 444 and the optical fibers 442. In certainembodiments, the strength layer 446 is made of a tensile reinforcingmaterial such as aramid yarn.

As shown at FIG. 43, the outer jacket 444 has been stripped to exposeabout 25-35 millimeters of the optical fibers 442. The strength layer446 is shown separated from the fibers 442 and folded back over thejacket 444. The optical fibers 442 have been sorted and arranged into arow. A material such as tape 448 can be used to hold the coated opticalfibers 442 in the desired order. In the depicted embodiment, the opticalfibers 442 include twelve fibers arranged in a planar 12×1 array. Inother embodiments, other types of instant adhesive can be used to securethe optical fibers 442 in the desired order sequence.

FIG. 44 shows the strength layer 446 trimmed to a suitable length forsecurement to the multi-fiber connector 430. In one embodiment, thestrength layer 446 is trimmed to a length of about 4-6 millimeters.

FIG. 45 shows a thermoplastic over molded section 450 is molded over theordered optical fibers 442. In one embodiment, the over molded section450 is separated from the cable jacket 444 by a distance d1 in the rangeof about 9-13 millimeters. In certain embodiments, the over moldedsection 450 has a length d2 of about 3-6 millimeters. In certainembodiments, d1 can equal about 11 millimeters and d2 can equal about4.5 millimeters.

FIG. 46 shows the spring 439 of the multi-fiber connector 430 insertedover the optical fibers 442 of the cable 440. FIG. 47 shows coatings ofthe optical fibers 442 stripped from the optical fibers 442. In thisway, bare glass portions of the optical fibers 442 are exposed. Incertain embodiments, the bare glass portions can start at a point spaceda distance d3 of about 15-17 millimeters from the end of the cablejacket 444. After the stripping step, the bare optical fibers can becleaned and inspected for defects. FIG. 48 shows the optical fibers 442after the optical fibers 442 have been cleaved (e.g., laser cleaved). Incertain embodiments, after cleaving, the bare fiber portions of theoptical fibers 442 have a length d4 of about 5 millimeters. Aftercleaving, the fiber optic cable 440 is ready to be spliced to theoptical fibers 424 supported by the multi-fiber ferrule 422.

The assembly of the multi-fiber ferrule 422 and the optical fibers 424is shown at FIG. 49. To access the depicted assembly, the ferrule 422can be bowl fed and picked and placed at the output of the bowl. It willbe appreciated that the front end 426 of the ferrule 422 has beenpreprocessed and the end faces of the optical fibers 424 at the frontend 426 have been pre-polished. Additionally, in the bowl, the end face426 is preferably protected by a dust cap. An automated system can scanand read information provided on the ferrule 422 (or on the dust cap)that identifies the ferrule 422. The automated system can also removethe packed dust cap, rotate the ferrule 422 in a vision system toaccurately find the window on the ferrule, and can accurately positionthe ferrule in a gripper/carrier without touching or damaging the frontface 426 of the ferrule 422.

FIGS. 50 and 51 show steps for preparing the optical fibers 424 of themulti-fiber ferrule 422 for splicing to the optical fibers of themulti-fiber cable 440. To prepare the ferrule 422 and the optical fibers424 for splicing, coatings of the optical fibers 424 are stripped toexpose bare glass portions of the optical fibers 424 as shown at FIG.50. Also, the optical fibers can be cleaned and inspected for defects.As shown at FIG. 51, the bare optical fibers are then cleaved to alength d5 of preferably 5 millimeters or less. As shown at FIG. 51,buffered portions of the optical fibers project outwardly from the rearside of the ferrule 422 by a distance less than about 1 millimeter. Inthe depicted embodiment of FIG. 51, a boot 450 is shown schematicallypositioned within the ferrule 422 adjacent the rear end 428. The boot450 is configured to provide bend radius protection and strain relief tothe optical fibers 424 adjacent the rear end 428 of the ferrule 422.Preferably, the boot 450 projects no more than 2 millimeters rearwardlyfrom the rear end 428 of the ferrule 422. In the depicted embodiment, arear end of the boot is flush with the rear end 428 of the ferrule 422.In other embodiments, the rear end of the boot 450 can be recessedwithin the ferrule 422 so as to be forwardly offset from the rear end428 of the ferrule. This way, the boot 450 provides protection of theoptical fibers 424 without interfering with subsequent splicingoperations that take place in close proximity to the rear end 428 of theferrule 422.

FIG. 52 shows the stub optical fibers 424 of the ferrule 422 beingfusion spliced to the optical fibers 442 of the multi-fiber cable 440. Afusion splicing tray 600 is used to provide alignment of the opticalfibers 442, 424 and to protect various components from exposure to thefusion splicing arc. The tray has a length L, a width W and a height H.The width W extends in a direction parallel to the optical fibers 442,424 when the optical fibers 442, 424 are supported on the tray 600. Asshown at FIG. 53, when viewed in top plan view, the tray 600 has anarrowed, waist region 602 (i.e., a narrowed region or a waist region)at an intermediate location along the length L. The narrow, waist region602 has a reduced width W1 that is smaller than the width w of the tray600 at the ends of the tray 600. The narrow region 602 is provided bynotches 603 that extend into a main body of the tray 600 at oppositesides of the tray 600. In other embodiments, only one of the notches maybe provided to form the narrowed region 602.

The narrowed region 602 corresponds to a splicing region/zone 613 wherethe optical fibers 442, 424 are routed across the tray 600 and fusionspliced together. Alignment structures in the form of v-grooves 604 areprovided at a top side of the tray 600 adjacent the narrowed region 602for supporting the optical fibers 442, 424 and for coaxially aligningthe optical fibers 442, 424. In other embodiments, active alignmentequipment of the type previously described can also be used to coaxiallyalign the optical fibers. The narrowed region 602 provides clearance forallowing the optical fibers 442 to be spliced to the optical fibers 424in close proximity to the rear end 428 of the ferrule 422.

The tray 600 also includes structure for preventing debris fromcontaminating the splicing region 613. As shown at FIGS. 52 and 53,arc/fusion splicing electrodes 610 fit within a slot 612 that extendsalong the length L of the tray 600. The slot 612 narrows to a narrowedportion 615 as the slot passes the region where the v-grooves 604support the optical fibers 442, 424. The narrowed portion 615corresponds to the spicing region 613. The electrodes 610 are positionedon opposite sides of the splicing region 613 of the tray 600. Free endsof the optical fibers 442, 424 that are intended to be spliced togetheroverhang the narrowed portion 615 of the slot 612. Contaminationreduction slots 616 are positioned adjacent to each of the sets ofv-grooves 604. Specifically, the contamination reduction slots 616 arepositioned between the v-grooves 604 and the narrowed portion 165 of theslot 612. Preferably, the contamination reduction slots 616 extendcompletely through the height H of the tray 600 and allow contaminationto fall through the tray 600 rather than contaminating the ends of thefibers prior to splicing. Rails 618 are positioned between thecontamination reduction slots 616 and the narrowed portion 615 of theslot 612. The rails 618 are preferably slightly recessed relative to thedepth of the v-grooves 604. For example, as shown at FIG. 54 a, topsides 620 of the rail 16 are positioned lower than valleys 622 of thev-grooves 604. It will be appreciated that the depth of the slot 612extends substantially below the top sides 620 of the rails 618. Therails 618 function to catch debris before the debris enters the slot612.

The slot 612 is preferably deep enough for an electric arc to be passedbetween the electrodes 610 and used to heat and fuse together the endsof the optical fibers 442, 424. By recessing the electrode 610 withinthe slot 612, the tray 600 functions to shield the ferrule 422 and othercomponents from heat associated with the arc. Prior to fusing the endsof the optical fibers together via the arc generated across theelectrodes 610, a short burst of electric arc can be used to clean thesplice zone. The v-grooves can be defined in a ceramic portion of thetray 600 (or the tray can be fully made of ceramic or like materials)and can be used to provide final alignment of the optical fibers 442,424. The tray 600 can also protect the areas outside the splice zonefrom unwanted exposure to the electric arc. The arc provided between theelectrode 610 reflows the glass of the optical fibers and therebyprovides a splice thereinbetween. In other embodiments, alternative heatsources may be used as well.

After the fusion splicing process has been completed, the components areremoved from the tray 600 and the fusion splice area is preferably overmolded with a protective coating material such as an ultraviolet curedpolymer. The ultraviolet cured polymer is preferably cured to ensurethat it is stable to temperatures exceeding 100° C. The ferrule 422 isthen configured to be a female component (see FIG. 56) or a malecomponent (see FIG. 57). A spring clip can be mounted adjacent the backside of the ferrule as needed for either the female configuration or themale configuration of the connector.

Subsequently, the ferrule 424 and the spring are loaded into the frontportion 432 a of the connector housing 432 (see FIG. 58) and the rearportion 432 b of the connector housing 432 is secured to the frontportion 432 a thereby retaining the spring and ferrule therein (see FIG.59). The strength layer 446 of the cable 440 is then secured (e.g.,crimped with crimp ring 460) to a rear stub 462 of the rear portion 432b of the connector housing 432 (see FIGS. 59 and 60). Next, the boot 434is installed over the crimp band as shown at FIG. 61 and the dust cap435 is installed over the front end of the connector 430 as shown atFIG. 62.

FIGS. 63-67 show a sequence for splicing an optical fiber stub 24 gsupported by a ferrule 22 g to an optical fiber 216 g of a fiber opticcable. The optical fiber stub 24 g includes a bare fiber segment 46 gand a coated fiber segment 48 g. The optical fiber 216 g includes a barefiber segment 291 g and a coated portion 293 g. The fiber optic cablealso includes a buffer tube 221 g that surrounds the coated portion 293g of the optical fiber 216 g. FIG. 63 shows the optical fiber 216 gcoaxially aligned with the optical fiber stub 24 g in preparation forsplicing. FIG. 64 shows the optical fiber stub 24 g spliced to theoptical fiber 216 g. FIG. 65 shows a protective layer 232 g over moldedor otherwise applied over a splice location 218 g between the opticalfiber 216 g and the optical fiber stub 24 g. The protective layer 232 gextends from a rearward end of the ferrule 22 g to a forward end of thebuffer tube 221 g. FIG. 66 shows a body 500 having a front hub portion502 and a rear hub portion 504. The front hub portion 502 includes flatsides 506 and an inter lock portion 508, such as a dove tail. In certainembodiments, the front hub portion 502 of the body 500 can bemanufactured of a relatively hard plastic material such as a polyamidematerial. As shown at FIG. 66, the front hub portion 502 is pre-molded(e.g., overmolded) over the ferrule 22 g prior to the optical fiber stub24 g being spliced to the optical fiber 216 g. Marking can be placed onthe flat sides 506 of the front hub portion 502 to aid in tuning. Incertain embodiments, the front hub portion 502 has 6 or 8 flats. Theflat 506 closest to the core offset direction can be marked for lateridentification when the ferrule 22 g assembly is loaded in a connectorbody. Thus, the marked flat 506 can be used to identify (either manuallyor automatically) the core offset direction of the ferrule 22 g.

After the front hub portion 502 has been molded over the ferrule 22 gand the fibers 24 g, 216 g have been spliced together, as shown at FIG.64, the rear hub portion 504 can be over molded within and over thefront hub portion 502 to form a composite hub 230 g that is coupled tothe ferrule 22 g and contains the splice location 218 g. The rear hubportion 504 is overmolded to encapsulate the dove tail of the front hubportion 502 and the protective layer 232 g. In the depicted embodiment,the rear hub portion 504 completely encapsulates the protective layer232 g and includes a rearward portion that closes around the buffer tube221 g. The front end of the front hub portion 502 is not covered by therear hub portion 504. In this way, the forward end of the front hubportion 502 forms a front nose of the composite hub 230 g. FIG. 67 showsan alternative embodiment of the rear hub portion 504. Referring to FIG.68, the ferrule 22 g is shown without the rear hub portion 504 and thebuffer tube 221 g removed. FIGS. 69-70 are side and cross-sectionalviews of FIG. 68. FIG. 71 is a top view of FIG. 69 and FIG. 72 is aperspective view of the alternative embodiment. FIGS. 73-74 are side andcross-sectional view of FIG. 72.

It will be appreciated that the composite hub 230 g can be used in anyof the fiber optic connectors in accordance with the principles of thepresent disclosure. Additionally, in certain embodiments, the rear hubportion 504 is formed of a hot melt adhesive that can be applied andcured at relatively low molding temperatures and pressures. Rear hubportion 504 can also be formed from a UV curable material (i.e., thematerials cure when exposed to ultraviolet radiation/light), forexample, UV curable acrylates, such as OPTOCAST™ 3761 manufactured byElectronic Materials, Inc. of Breckenridge, Colo.; ULTRA LIGHT-WELD®3099 manufactured by Dymax Corporation of Torrington, Conn.; and 3M™SCOTCH-WELD™ manufactured by 3M of St. Paul, Minn. The use of UV curablematerials is advantageous in that curing can occur at room temperaturesand at generally lower pressures (e.g. less than 30 kpsi, and generallybetween 20-30 kpsi). The availability of low pressure curing helps toensure that the components, such as the optical fiber(s), being overmolded are not damaged during the molding process. In certainembodiments, an injection molding process can be used to apply and formthe rear hub portion 504 from a UV curable material about the protectivelayer 232 g and the front hub portion 502. In certain embodiments, therear hub portion 504 is made of a material having different materialproperties than the material of the front hub portion 502. For example,the rear hub portion 504 can be softer or more resilient than the fronthub portion 502. The composite nature of the hub 230 g simplifies themolding operation. The front hub portion 502 can be over molded using anover molding process having higher temperatures and pressures than theover molding process used to form the rear hub portion 504. The fronthub portion can interlock with the ferrule 22 g.

In some embodiments, the composite construction of the composite hub 230g relies on the front hub portion 502 to provide mechanical strength andprecision and for securement of the composite hub 230 g to the ferrule22 g (e.g., the front hub portion 502 is bonded to the ferrule 22 g). Insome embodiments, the composite construction of the composite hub 230 grelies on the rear hub portion 504 for securement of the composite hub230 g to the buffer tube 221 g and for providing additional protectionwith respect to the splice location 218 g and the bare fiber segments 46g, 291 g.

In one embodiment, the front hub portion 504 can be mounted (e.g., overmolded) on the ferrule 22 g prior to polishing, cleaning, cleaving,stripping, tuning, active alignment and splicing of the ferruleassembly. In this way, the front hub portion 504 can be used tofacilitate handling and positioning of the ferrule 22 g during thevarious processing steps. In one example, a flat of the front hubportion 504 can be marked for tuning purposes.

In one embodiment, the rear hub portion 504 can be overmolded toencapsulate the dove tail of the front hub portion 502 and theprotective layer 232 g in an injection mold assembly 700, as shown inFIGS. 75-81. As shown, mold assembly 700 includes an upper mold assembly702 and a lower mold assembly 704. The upper mold assembly 702 includesan upper mold block 706 attached to and operated by the mold assembly700 via an upper frame piece 708. Likewise, the lower mold assembly 704includes a lower mold block 710 attached to and operated by the moldassembly 700 via a lower frame piece 712. The actuation of the framepieces 708, 712 may be manual or automatic.

In one embodiment, the upper and lower mold blocks 706, 710 are formedfrom a UV light transmissive material, such as Dupont™ TEFLON® FEP 100Fluoropolymer Resin. This material has been found to have sufficient UVlight transmission characteristics above 300 nm wavelengths atthicknesses corresponding to those used for mold blocks 706, 710 (e.g.about 50-75% transmissivity for material thicknesses between 1-2millimeters at UV wavelengths of 365 nm at an initial intensity of about1.7-2.0 watts/square centimeter). Also, TEFLON® has beneficialproperties that allow for the mold blocks 706, 710 to be molded withcomplex mold cavity shapes while also being resistant to adhesion to thecured material in the mold cavities. This material also allows for themold blocks 706, 710 to have mating surfaces that are sufficientlyformed to avoid undesirable flashing on the molded part.

The upper mold block 706 and the lower mold block 710 may have aplurality of cooperating cavity portions 714, 716 for forming the rearhub portion 504. As can be most easily seen at FIGS. 80-81, the uppermold block 706 has an upper cavity portion 714 that cooperates with alower cavity portion 716 on the lower mold block 710. As shown, theupper cavity portion 714 includes a mold cavity portion 714 a, a ferrulesecuring portion 714 b, and a buffer tube pocket portion 714 c whilelower cavity portion 716 includes a mold cavity portion 716 a, a ferrulesecuring portion 716 b, and a buffer tube pocket portion 716 c. When theupper and lower mold blocks 706, 710 are pressed against each other viaoperation of the frame pieces 708, 712, the upper and lower cavityportions 714, 716 form a mold cavity with portions 714 a, 716 a, andsecure the ferrule 22 g with portions 714 b, 716 b. The buffer tubepockets 714 c, 716 c create a passageway for buffer tube 221 g duringthe molding process.

It is noted that mold blocks 706, 710 may include upper and lower vacuumchannels 724, 726, connected to a vacuum source (not shown), forsecuring the ferrules 22 g against portions 714 b, 716 b to preventunwanted movement during the molding process. As shown, channels 724,726 extend along the mold blocks 706, 710 to each of the cavity portions714 b, 716 b. It is further noted that the contours of the mold cavityportions 714 a, 716 a match the shape of the full formed rear hubportion 504 shown in FIGS. 67 and 72-74. In the embodiment shown atFIGS. 75-79, there are twelve pairs of cooperating mold cavity portions714, 716 such that twelve rear hub portions 504 may be formedsimultaneously by the mold assembly 700.

As shown, the mold assembly 700 further includes a series of injectionneedles 718. In one embodiment, there is one injection needle 718 foreach mold cavity. However, more than one injection needle may beprovided for each mold cavity. The injection needles 718 are forinjecting uncured material for the rear hub portion 504 into the moldcavities formed once the mold blocks 706, 710 have been pressed againsteach other. In one embodiment, the lower mold block 710 includespassageways 752 which provide a fluid communication path between theinjection needles 718 and the corresponding mold cavities. It is notedthat the injection needles 718 may be made from a material that isnon-transmissive to UV light, such as a metal, in order to preventunwanted or premature curing within the injection needle 718.

Referring to FIGS. 78-79, a valve 720 having a passageway 722 isprovided within the passageway 752 of the lower mold block 710. In oneembodiment, the valve 720 is made from a material that isnon-transmissive to UV light, such as opaque silicone or EPDM rubber.Such a material will help to prevent uncured material within the valve720 and/or injection needle 718 from being undesirably cured during themolding process. In one embodiment, the valve 720 is configured as aone-way valve such that uncured material may flow into the mold cavitythrough passageway 722, but may not flow from the mold cavity back intothe injection needle 718.

In one embodiment, valve 720 is made from a flexible polymeric materialand is configured such that passageway 722 opens when a thresholdpressure exerted by the uncured material within injection needle 718 isexceeded, and closes when pressure is sufficiently reduced. In oneembodiment, valve 720 is a slit-type valve. It is noted that FIGS. 78-79show the valve 720 in an open position with the passageway 722 beingshown with an exaggerated size for the purpose of clarity. The combinedfeatures of valve 720 also result in a molded rear hub portion 504 thatis free from legs or runners that would normally need to be removed froma molded product after the molding process.

Additionally, each injection needle 718 may be configured to be insertedthrough its respective valve 720 and into the cavity area 716 a, 714 awhen injecting molding material into the cavities. In such aconfiguration, the injection needles 718 may be retracted out of themold cavities after the cavities are sufficiently filled and before thecuring process begins. It is also noted that mold assembly 700 may alsobe configured to draw a slight vacuum on the uncured material within theinjection needles 718 after filling the mold cavity to help ensure thatuncured material is removed further away from the area of UV lightexposure.

As shown, the mold assembly 700 further includes a plurality of UV lightfixtures 728 (728 a, 728 b, 728 c). The UV light fixtures 728 are fordirecting UV light towards the mold cavity portions 714 b, 716 b suchthat UV sensitive material within the cavities can be cured during themolding process. In the embodiment shown, three UV lights are arrangedto direct UV light onto each mold cavity from various angles. It isnoted that more or fewer UV lights could be used. In the embodimentshown, the UV light fixtures 728 include LED bulbs that emit 365nanometer (nm) ultraviolet light at 3 watts per square centimeter. It isnoted that other wavelengths and intensities may be used, and that thechosen wavelength and intensity of the lights is generally a function ofthe selected materials used for the mold blocks and the rear hub portion504. Referring to FIG. 75, a total of 14 sets of UV light fixtures 728a, 728 b, 728 c are provided for the twelve mold cavities. While 12 setsdirectly expose light on a particular mold cavity, an additional set ofUV light fixtures is provided at each end of the mold blocks 706, 708 toensure that the outermost mold cavities are exposed to the same level ofUV light as the inner mold cavities.

As most easily seen at FIG. 78, the upper mold block 708 has a pluralityof cavities 730 for receiving UV lights 728 a. The UV lights 728 a areoriented to direct light downward onto the upper cavity portion 714 b.The lower mold block 710 has recesses 732 and 734 for receiving UVlights 728 b and 728 c, respectively. The recesses 732 and 734 aredisposed angles due to the presence of the injection needles 718, valves720, and the ejector pins (discussed later). It is noted that since thevalves 720 and injection needles 718 may not UV light transmissive, thatUV lights 728 b and 728 c must be oriented to ensure the mold cavity issufficiently exposed to UV light around these components. As mentionedabove, because the mold blocks 706, 710 are UV light transmissive, theUV lights are able to cure the molded material within the mold cavitieswhile the mold blocks 706, 710 are closed together.

Once the mold material has been sufficiently cured to form the rear hubportions 504, the vacuum that secures the ferrules may be discontinuedand the mold blocks 706, 710 may be separated. In order to facilitateremoval of the composite hub 230 g from the mold blocks 706, 710, themold assembly 700 may be provided with an ejector assembly 736. In oneembodiment, the ejector assembly 736 includes an upper ejector assembly738 located in the upper mold assembly 702 and a lower ejector assembly740 in the lower mold assembly 704. As shown, each of the ejectorassemblies 738, 740 includes a plurality of ejector pins 740, 742connected to a common support rail 744, 746. The number of ejector pins738 corresponds to the number of mold cavities. Accordingly, the uppermold block has a passageway 748 for the ejector pins 740 while the lowermold block has a passageway 750 for the ejector pins 742. To remove thehub 230 g from the mold blocks 706, 710, the ejector pins 740, 742 aredriven into the passageways 748, 742 until they contact and dislodge theferrule portion 22 g located within cavity portions 714 b, 716 b. Thesupport rails 744, 746 that drive the pins 740, 742 may be eithermanually or automatically actuated. It is noted that the ejector pins740, 742 may be manufactured from a UV light transmissive material so asto minimize interference with the curing process. Examples of UV lighttransmissive materials for the ejector pins 740, 742 are transparentglass and polycarbonate. It is also noted that the ejector pins can beremoved or partially retracted away from the cavities in the mold blocks706, 710 during the curing process to reduce interference with UV lighttransmission.

Referring to FIG. 82, an injection molding process 1000 is shown inwhich mold assembly 700 may be used to form an overmolded ferrule andcomposite hub. In a first step 1002, ferrules with pre-molded collars,which may be spliced to buffered fibers of cable assemblies, arepositioned over the cavities in the mold assembly. In a second step1004, a vacuum is turned on to hold the ferrules and prevent unwantedmovement in either axial or rotational modes. It is noted that thevacuum may be active before the ferrules with pre-molded collars arepositioned over the cavities. In a third step 1006, once all of thedesired cavities in the mold are filled, the mold blocks of the moldassembly are closed together. In another step 1008, EFD or similardispensing units are used to deliver UV material into the mold cavitiesunder low pressure through the injection needles and associated valves.The amount of material injected may be calculated or empiricallydetermined using trials to optimize the fill volume without causingunwanted flash or other protrusions. In another step 1010, the UV lightsare activated and turned on at an intensity and duration optimized tofully cure the materials with a minimum cycle time. In one embodiment,the cycle time is about 10 seconds when using a 365 nm UV light at 3watts per square centimeter. In one embodiment, the intensity of the UVlight is initially low, for example for the first 5 seconds of a 10second cycle, and is then raised to a higher value. Such an approach isbeneficial where the material to be cured may be sensitive tovolatilization if exposed to the higher intensity value initially. Inanother step 1012, the mold blocks are separated. Ejector pins may bealso be used during separation at the location of the ferrule todislodge the overmolded ferrule and hub. In another step 1014, theovermolded ferrule and hub is withdrawn from the mold assembly. It isnoted that other injection molding applications may be used with theabove described mold assembly and process, and that the disclosure isnot limited to injection molding parts and components relating tooptical fiber technology.

FIGS. 83 and 84 show another ferrule assembly 20 h and hub 230 h inaccordance with the principles of the present disclosure. The ferruleassembly 20 h includes a ferrule 22 h supporting an optical fiber stub24 h. The optical fiber stub 24 h is fusion spliced to an optical fiber216 h of a fiber optic cable 212 h at a splice location 218 h. The hub230 h mounts to the rear end of the ferrule 22 h and covers the splicelocation 218 h. The hub 230 h includes a front hub portion 502 h and arear hub portion 504 h. The rear hub portion 504 h includes an outer hubshell 900 defining an interior cavity 902. The outer hub shell 900includes an axial/longitudinal slot 904 that allows the outer hub shell900 to be inserted laterally over the optical fiber stub 24 h and theoptical fiber 216 h at the splice location 218 h after the optical fiberstub 24 h has been spliced to the optical fiber 216 h. The outer hubshell 900 also includes a port 906 for allowing the outer hub shell 900to be filled with an over mold material (e.g., a UV curable material, ahot melt material, a thermoplastic material, an epoxy material, athermoset material, or other materials). The over mold material 908 isnot shown at FIGS. 83 and 84, but is depicted at FIG. 93. The outer hubshell 900 can function as a mold for shaping the over mold material 908around the splice location 218 h and along the lengths of the opticalfiber 216 h and the optical fiber stub 24 h. A temporary mold piece canbe used to cover the axial slot 904 as the over mold material 908 isinjected into the outer hub shell 900 through the port 906. The outerhub shell 900 remains a permanent part of the hub 230 h after the overmold material 908 has been injected therein.

The front hub portion 502 h can be over molded on the ferrule 22 h orotherwise mounted on the ferrule 22 h. Portions of the front hub portion502 h can interlock with corresponding slots or other openings in theside of the ferrule 22 h to limit axial movement of the front hubportion 502 h relative to the ferrule 22 h. As shown at FIGS. 85 and 86,the front hub portion 502 h includes a front end 910 and a rear end 912.The rear end 912 is forwardly offset from a rear end 28 h of the hub 230h. In this way, the rear end 28 h of the hub 230 h projects rearwardlyfrom the rear end 912 of the front hub portion 502 h. In certainexamples, the front hub portion 502 h is made of a harder, more ruggedmaterial than the over mold material 908. In certain examples, the fronthub portion 502 h can be over molded on the ferrule 22 h using a highertemperature and/or higher pressure molding process as compared to themolding process used to install the over mold material 908 in the outerhub shell 900. Still referring to FIGS. 85 and 86, the front hub portion502 h can include a series of flats 914 used for indexing or otherwiserotationally positioning the ferrule assembly 20 h in a connector suchas the LC connector 990 of FIGS. 92 and 93. The front hub portion 502 hcan also include front chamfered sections 916 for seating the hub 230 hwithin the connector 990.

The front hub portion 502 h can be over molded on the ferrule 22 h priorto stripping, cleaning, cleaving, active alignment, and splicingoperations. In this way, the front hub portion 502 h can be used tofacilitate handling of the ferrule assembly 20 h during the variousoperations described above. During active alignment of the optical fiberstub 24 h and the optical fiber 216 h, the front end 910 of the fronthub portion 502 h can abut against a stop, side wall or other structureof the ferrule holder (e.g., see ferrule holder 240 of FIG. 19) toensure the ferrule 22 h is positioned at a precise axial positionrelative to the ferrule holder. Thus, the front hub portion 502 h can beused as a positive stop for controlling axial positioning of the ferrule22 h during the various operations described above.

In certain embodiments, the outer hub shell 900 abuts against the rearend of the front hub portion 502 h. As shown at FIG. 93, the outer hubshell 900 can include open regions 918 (internal cavities, internalslots, internal recesses, etc.) that axially overlap the rear end 28 hof the ferrule 22 h for allowing the over mold material 908 to fill thisregion and axially overlap the rear end 28 h of the ferrule 22 h. Incertain examples, this type of configuration can provide bettersecurement of the ferrule 22 h. In certain examples, the outer hub shell900 is a molded polymeric part such as an injection molded part. Theouter hub shell 900 can be made of a material that is harder and moredurable/robust than the over mold material 908 so as to reinforce therear hub portion 504 h and to protect and contain the over mold material908. In the case where the over mold material 908 is UV curable, theouter hub shell 900 can be manufactured of a material that istransmissive with respect to UV light such that the over mold material908 can be cured by transmitting UV light/radiation through the outerhub shell 900.

FIGS. 87 and 88 show another ferrule assembly 20 i and hub 230 i inaccordance with the principles of the present disclosure. The ferruleassembly 20 i and hub 230 i can have the same construction as theferrule assembly 20 h and hub 230 h except the hub 230 i includes anouter hub shell 900 i having a male end 920 that fits within a femalereceptacle 922 defined at a back side of a front hub portion 502 i. Themale end 920 and the female receptacle 922 can have complementaryshapes. As depicted, the male end 920 and the female receptacle 922 eachinclude a series of flats that prevent relative rotation between theouter hub shell 900 i and the front hub portion 502 i. The male end 920of the outer hub shell 900 i is best shown at FIG. 89.

FIG. 90 shows a further ferrule assembly 20 j and hub 230 j inaccordance with the principles of the present disclosure. The ferruleassembly 20 j and the hub 230 j have the same basic configuration as theferrule assembly 20 h and hub 230 h except the hub 230 j includes anouter hub shell 900 j having a two-piece construction. The two pieces ofthe outer hub shell 900 j mate together with a splice location 218 jcaptured thereinbetween to form the outer hub shell 900 j.

FIG. 91 shows an alternative outer hub shell 900 k that can be used withthe ferrule assembly 20 i and front hub portion 502 i of FIGS. 87 and88. The outer hub shell 900 k includes two intermating half-pieces 950that cooperate to define an internal chamber/cavity 902 k for receivingovermold material. A port 906 k for filling the chamber/cavity 902 kwith overmold material is defined by at least one of the half-pieces950. The half-pieces 950 cooperate to define a male end 920 k at thefront end of the outer hub shell 900 k. Alignment features such as posts956 and corresponding openings 958 ensure proper alignment between thehalf-pieces 950 of the outer hub shell 900 k during assembly.

FIGS. 92 and 93 show the connector 990 that includes the ferruleassembly 20 h and the hub 230 h. The connector 990 includes a mainconnector body 991 having a standard LC-style form factor and mechanicallatching arrangement. The connector 990 also includes a spring 992 forbiasing the ferrule assembly 20 h and the hub 230 h in a forwarddirection such that the chamfered section 916 of the hub 230 h seatswithin the main connector body 991. The connector 990 further includes arear housing 993 that retains the spring within the main connector body991. The connector 990 further includes a crimp 996 for securing cablestrength members to the rear housing 993, and a boot 998 for providingstrain relief and fiber bend radius control at the cable-to-connectorinterface.

While it is preferred for both the ferrule assembly manufacturingprocess and the fiber optic cable and connector manufacturing process tobe fully automated, it will be appreciated that certain steps of eitherof the processes can be performed manually. Additionally, while it ispreferred for the splicing technology and processing disclosed herein tobe used in a factory setting, such technology and processing can also beused away from the factory in the field for field splicing applications(e.g., at a customer location). In other words, the fusion splice,splice protection, over molding, strength member fixation and assemblyof the connector part or parts can be performed outside a factory, forexample, at a customer site. Also, while the processing was describedwith respect to patch cords, it will be appreciated that the sameprocessing technology can be used to attach a connector to any type offiber optic cable of cord. Moreover, while SC connectors are shown, itwill be appreciated that the technology is applicable to any type offiber optic connector.

Another aspect of the present disclosure relates to a method for massproducing and distributing fiber optic connector assemblies. Asignificant aspect of the method relates to the centralizedmanufacturing of large quantities of ferrule assemblies each having aferrule supporting a stub fiber. In certain examples, the volume offerrule assemblies manufactured at a given centralized manufacturinglocation can exceed a volume of 500,000; 1,000,000; 2,000,000; or3,000,000 ferrule assemblies. By manufacturing such large volumes offerrule assemblies at one centralized location, the ferrule assembliescan be made efficiently and considerable capital investment can be madein premium quality manufacturing equipment and processes. For example,the ferrule assemblies can be manufactured in a factory location usingthe highly precise polishing technology and equipment. Moreover, highquality and precisely toleranced ferrules and stub fibers can beeffectively matched to provide the ferrule assemblies extremely highlevels of optical performance. The large volumes of ferrule assembliesmanufactured at a given centralized location provide the manufacturingefficiency for making this type of operation feasible. Examples of suchhigh quality manufacturing operations and equipment are disclosedthroughout the present disclosure. The centralized manufacturing alsoenables substantial investment in automation.

The method also relates to distributing ferrule assemblies manufacturedat a centralized location to regional factories/mass productionlocations located closer to the intended point of sales. The relativesmall size of ferrule assemblies allows large volumes of such ferruleassemblies to be effectively shipped at relatively low costs. High costsassociated with extensive shipment of cable can be significantlyreduced. At the regional locations, connectorized fiber optic cableassemblies can be effectively and efficiently mass produced in a factoryenvironment by splicing the ferrule assemblies to cables as describedherein. The high level of precision provided in the ferrules, opticalfibers, splicing techniques and manufacturing processes used at thecentral location effectively compensates for any losses associated withadding splices to the mass produced fiber optic connector assemblies.Once again, the high volumes of ferrule assemblies manufactured at thecentralized locations provide the justification for making the capitalexpenditures necessary to provide the level of equipment quality,automation and manufacturing precision to make this manufacturing anddistribution system feasible.

Aspects of the present disclosure allow ferrule assemblies to bemanufactured in large volumes at manufacturing locations where processis most cost effective. The ferrule assemblies, which are small in size,can be efficiently shipped in bulk to factory/assembly locations closerto customer locations where the ferrule assemblies can be spliced tofiber optic cables and final connector assembly can take place. In thisway, shipping of the cable itself (which tends to be larger in size andweight) can be minimized. Also, final assembly can be made closer tocustomer locations thereby decreasing lead times. Global supply chainscan also be enhanced.

While various specific dimensions are provided above, it will beappreciated that the dimensions are applicable to some embodiments andthat other embodiments within the scope of the present disclosure mayuse dimensions other than those specifically provided. Similarly, whilevarious manufacturing tolerances are provided above, it will beappreciated that the manufacturing tolerances are applicable to someembodiments and that other embodiments within the scope of the presentdisclosure may use manufacturing tolerances other than thosespecifically provided. The above specification, examples and dataprovide a description of the inventive aspects of the disclosure. Manyembodiments of the disclosure can be made without departing from thespirit and scope of the inventive aspects of the disclosure.

1. (canceled)
 2. A fiber optic connector assembly comprising: aconnector body having a front end and a back end; a ferrule positionedat least partially within the connector body adjacent the front end ofthe connector body; a first optical fiber that forms an optical fiberstub corresponding to the ferrule, the first optical fiber including afirst portion secured within the ferrule and a second portion thatextends rearwardly from the ferrule; a boot positioned adjacent the backend of the connector body; and a second optical fiber fusion spliced tothe first optical fiber at a splice location positioned within 5millimeters of a rear end of the ferrule.
 3. The fiber optic connectorassembly of claim 2, further comprising a hub secured on the ferrule,the hub being movable unitarily with the ferrule.
 4. The fiber opticconnector assembly of claim 3, further comprising a spring biasing theferrule and hub towards the front end of the connector body.
 5. Thefiber optic connector assembly of claim 4, wherein the splice locationis provided between the ferrule and a rear end of the spring.
 6. Thefiber optic connector assembly of claim 3, wherein the hub is ofinjection molded construction.
 7. The fiber optic connector assembly ofclaim 3, wherein the hub includes keying structure to mount the ferruleat a desired rotational position relative to the connector body.
 8. Thefiber optic connector assembly of claim 2, wherein the second opticalfiber is fusion spliced to the first optical fiber at a factory.
 9. Thefiber optic connector assembly of claim 2, wherein the first opticalfiber has better core concentricity as compared to the second opticalfiber.
 10. The fiber optic connector assembly of claim 2, wherein thefirst optical fiber is offset relative to the ferrule in a core offsetdirection; and wherein the ferrule is marked to indicate the core offsetdirection.
 11. The fiber optic connector assembly of claim 10, wherein acore offset direction mark is printed on the ferrule.
 12. The fiberoptic connector assembly of claim 10, wherein a core offset directionmark is etched on the ferrule.
 13. The fiber optic connector assembly ofclaim 10, further comprising a hub secured on the ferrule, the hub beingrotationally positioned on the ferrule based on the core offsetdirection marked on the ferrule.
 14. The fiber optic connector assemblyof claim 13, wherein the hub includes keying structure to mount theferrule at a desired rotational position relative to the connector body.15. The fiber optic connector assembly of claim 2, wherein the ferruleincludes a multi-fiber ferrule; and wherein a plurality of opticalfibers including the first optical fiber having front portions securedwithin the multi-fiber ferrule and rear portions that project rearwardlyfrom the rear end of the ferrule.
 16. The fiber optic connector assemblyof claim 15, wherein a plurality of second optical fibers including thesecond optical fiber are spliced to the first optical fibers at splicelocations positioned within 5 millimeters of the rear end of theferrule.
 17. The fiber optic connector assembly of claim 2, wherein thefirst optical fiber has selected properties that are different than thesecond optical fiber.
 18. The fiber optic connector assembly of claim 2,wherein the fiber optic connector assembly has a total length less thanor equal to 57 millimeters, the total length being measured from thefront end of the connector body to a arear end of the boot.
 19. Thefiber optic connector assembly of claim 2, wherein the second opticalfiber is part of a fiber optic cable having a tensile strength structurethat anchors to the connector body.
 20. The fiber optic connectorassembly of claim 2, wherein a spring biases the ferrule towards thefront end of the connector body.
 21. The fiber optic connector assemblyof claim 20, wherein the splice location is positioned between forwardand rearward ends of the spring.